APE TM, TM Diesel Owners Manual PDF

Piaggio would like to thank you
for choosing one of its products. We have drawn up this booklet to show you all features of our product. Please read the booklet carefully before using
your vehicle. It includes information, suggestions and warnings regarding your vehicle. You will also be informed of features, details and devices that
will prove the excellence of your choice. We believe that if you follow our suggestions you will soon tune in with your vehicle and use it for a long time
at full satisfaction.
This booklet is an integral part of the vehicle, and upon sale, it should be transferred to the new owner.
Ape TM - Ape TM Diesel
Ed. 01_02/2012
INSTRUCTIONS
The instructions given in this booklet are intended to provide a clear, simple guide to using your scooter; details are also given of routine maintenance
procedures and regular checks that should be carried out on the vehicle at an Authorised PIAGGIO Dealer or Service Centre. The booklet also
contains instructions for simple repairs. Any operations not specifically described in this booklet require the use of special tools and/or particular technical
knowledge: to carry out these operations refer to any authorised PIAGGIO Dealer of Service Centre. Read this booklet carefully before using your
vehicle. Follow the instructions contained in this booklet for your personal safety and to ensure long-lasting use of your vehicle. Failure to observe these
instructions may cause personal injury or damage to the vehicle.
2
Personal safety
Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment
Sections marked with this symbol indicate the correct use of the vehicle to prevent dam-
aging the environment.
Vehicle intactness
The incomplete or non-observance of these regulations leads to the risk of serious

damage to the vehicle and sometimes even the invalidity of the guarantee.
The signs indicated on this page are very important, they highlight the parts of the booklet
that should be read with particular care. Each sign consists of a different graphic symbol,
making it quick and easy to locate the various topics.
3
4
INDEX
IDENTIFICATION......................................................................... 7 Demisting.............................................................................. 59
Vehicle identification number.................................................... 8 MIRRORS AND WINDOW GLASSES......................................... 61
SAFE RIDING.............................................................................. 11 Adjusting the mirror............................................................... 62
Safe drive.................................................................................. 12 Wipers and Brushes.................................................................. 62
Running-in period...................................................................... 12 INSIDE EQUIPMENT................................................................... 65
VEHICLE USE.............................................................................. 13 ELECTRICAL SYSTEM............................................................... 67
Checks...................................................................................... 14 Fuel version.............................................................................. 68
Before starting the engine......................................................... 18 Diesel version........................................................................... 68
Engine start up.......................................................................... 19 EMERGENCY.............................................................................. 71
Stopping the engine.................................................................. 21 Wheel replacement................................................................... 72
Starting difficulties..................................................................... 21 Maintenance instructions....................................................... 72
Gear position............................................................................. 22 MAINTENANCE........................................................................... 75
Driving Tips............................................................................... 23 Check engine oil level........................................................... 76
DOORS AND LOCKS.................................................................. 27 Oil change and oil filter replacement..................................... 76
Keys.......................................................................................... 28 Checking the brake fluid level................................................... 79
Door locking/unlocking by key............................................... 28 Gear box oil level...................................................................... 81
Front door windows................................................................... 29 Window washer fluid level......................................................... 83
Engine inspection port.............................................................. 30 Cooled fluid............................................................................... 83
SEATS AND SAFETY BELTS..................................................... 31 Changing the engine cooling fluid......................................... 84
Using the safety belts................................................................ 32 Checking and replacing the air cleaner element....................... 84
Fasting the safety belt........................................................... 33 Replacing the fuel filter............................................................. 85
Adjusting the safety belt........................................................ 34 Air bleeding........................................................................... 86
To release the safety belt...................................................... 34 Fuel exhaustion..................................................................... 86
INSTRUMENT PANEL AND CONTROLS................................... 35 Checking and replacing the pre-heating plugs.......................... 87
Handlebars............................................................................ 36 Fuses........................................................................................ 88
Steering wheel....................................................................... 39 Exhaust circulation system (EGR)......................................... 91
Controls..................................................................................... 43 Tyres......................................................................................... 91
Ignition switch........................................................................... 53 Pressure................................................................................ 92
GAUGES AND WARNING LIGHTS............................................ 55 Periods of inactivity................................................................... 92
Instrument unit and indicators................................................... 56 Troubleshooting / What to do if................................................. 98
AIR CONTROL SYSTEM............................................................. 57 SPARE PARTS AND ACCESSORIES........................................ 107
Heating.................................................................................. 58 Warnings................................................................................... 108
Heating and demisting........................................................... 59 TIPPER VERSION....................................................................... 109
5
System Operation..................................................................... 110
Warnings for Loading and Unloading Operations..................... 111
Scheduled Maintenance........................................................... 114
Extraordinary Maintenance....................................................... 116
Trouble-Shooting...................................................................... 117
Warning Plate Symbols............................................................. 120
technical sheet for EC conformity declaration........................... 123
Preface.................................................................................. 123
Equipment Layout................................................................. 124
Analysis of Risks Connected with the Layout and Operation
of the Equipment................................................................... 127
TECHNICAL DATA...................................................................... 135
Vehicle...................................................................................... 138
SCHEDULED MAINTENANCE - CHECKS................................. 149
Scheduled maintenance service............................................... 150
6
Chap. 01
Identification
7
Vehicle identification number (01_01, 01_02, 01_03)
The identification codes consist of a prefix followed by a number punched on the
chassis and on the engine, respectively.
Always quote the serial numbers when ordering spare parts.
The chassis identification number is located on the crossmember under the seat as
shown in the figure.
The frame identification code is:
01_01 ZAPT1000000001001
Check that the chassis prefix and number punched on the vehicle correspond to that
shown on the vehicle documents.
The engine identification number is printed as shown in the figure.
The first indicates the location of the plate on the diesel engine, while the second is
on the gasoline engine.
01_02
The gasoline version engine identification initials are:

ATM2M
The diesel version engine identification initials are:
1 Identification
LDW 422
01_03
8
CAUTION
1 Identification
BE REMINDED THAT ALTERING IDENTIFICATION REGISTRATION NUMBERS
MAY LEAD TO SERIOUS PENAL SANCTIONS (IMPOUNDING OF THE VEHICLE.
ETC.)
9
1 Identification
10
Chap. 02
Safe riding
11
Safe drive (02_01)
ENSURE THE SPARE WHEEL IS CORRECTLY SECURED TO THE SEAT
THROUGH THE RETAINING STRAP, IN ORDER TO PREVENT IT FROM MOVING
IN THE EVENT OF AN EMERGENCY STOP.
02_01
Running-in period
During the first 1000 km, do not twist the throttle fully open and avoid driving at constant
speed over long stretches of roads. After the first 1000 km gradually increase speed
until reaching the maximum performance.
2 Safe riding
12
Chap. 03
Vehicle use
13
Checks (03_01, 03_02, 03_03, 03_04)
Before using the vehicle, check:
1. That the oil and fuel (for fuel versions) tanks are filled.
2. The engine/transmission oil level (for diesel versions).
3. The brake fluid level.
4. That the tyre inflation pressure is correct.
5. Correct operation of side/taillights, headlights and turn indicators.
6. Front and rear brake operation.
7. Gearbox oil level (for petrol versions).
8. Electrolyte and battery charge check.
9. Check coolant (diesel version)
CAUTION
TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD.
TYRE PRESSURE
Front tyre pressure 2.5 atm
3 Vehicle use
Rear tyre pressure 4.5 atm
Fuel tank
14
The fuel filler cap is fitted with a lock.
3 Vehicle use
To open: insert the supplied key and turn it anticlockwise.
To close: put the filler cap back in position, turn the key clockwise and remove.
For petrol versions, the recommended fuel is as follows:
- unleaded petrol.
For diesel versions, the recommended fuel is as follows:
- diesel normally found on the market.
To this purpose please note that at low temperatures the paraffin elements contained
in diesel spontaneously dissociate, thereby decreasing fluidity. If it is not possible to
use winter type diesel, mix diesel with a special additive in the amounts indicated on
the container.
The additive must be poured into the tank before the diesel and before the process
described above since a late addition generates no effects.
CAUTION
• WHEN REFUELLING, KEEP THE CAP CLEAN FROM DUST AND DIRT.
CAUTION
BEFORE REFUELLING, STOP THE ENGINE. PETROL IS HIGHLY INFLAMMA-

BLE. DO NOT DROP PETROL ON HOT ENGINE PARTS. DO NOT SMOKE. KEEP
NAKED FLAMES AWAY: FIRE HAZARD. DO NOT INHALE PETROL FUMES.
15
FUEL
Total capacity: 15 litres
Fuel (Unleaded petrol)
03_01
Oil tank (for petrol versions)

The oil tank is provided with a light reserve indicator on the instrument panel.
To top up, remove cap «B» and pour in new oil.
CAUTION
USING OTHER TYPES OF OIL CAN COMPROMISE ENGINE DURABILITY.

03_02
Recommended products
3 Vehicle use
AGIP CITY TEC 2T

Oil for 2-stroke petrol engines
JASO FC, ISO-L-EGD Specifications
16
3 Vehicle use
Characteristic
Mixer oil (2.0 l)
RESERVE: 0.6 l
Removing the battery

The battery is located under the seat. The latter can be easily tilted removing the two
nuts «A» located at the two ends below the seat, as shown in the figure.
If it is necessary to remove the battery from its housing (for replacing or charging it),
disconnect the cables, remove nut «B» and release the battery from the locking
bracket «C».
CAUTION
03_03
NEVER DISCONNECT THE BATTERY WHEN THE ENGINE IS RUNNING TO

AVOID DAMAGING THE ELECTRICAL SYSTEM.
BATTERY ELECTROLYTE CONTAINS SULPHURIC ACID: AVOID CONTACT

WITH EYES, SKIN AND CLOTHES. IN THE EVENT OF ACCIDENTAL CONTACT,
RINSE WITH PLENTY OF WATER AND SEEK MEDICAL ADVICE
WARNING
03_04
USED BATTERIES ARE HARMFUL FOR THE ENVIRONMENT AND MUST BE

COLLECTED AND DISPOSED OF IN COMPLIANCE WITH THE LAW.
17
Installing a new battery
Make sure the terminals are fitted correctly. The battery is an electrical device that
requires careful checks and diligent maintenance.
CAUTION
DO NOT INVERT THE POLARITIES: DANGER OF SHORT-CIRCUIT AND FAULTS

IN THE ELECTRICAL DEVICES.
Checking electrolyte level

The electrolyte level must be checked frequently and must reach the maximum level.
Top up exclusively with distilled water.
If the battery requires topping up too frequently, check the electrical system - the bat-
tery is probably working in overload conditions, which will lead to rapid deterioration.
Before starting the engine

- Ensure that the parking brake is released.
- Ensure that the reverse gear control lever is forward or backward according to
whether you want to move forward or in reverse.
- Ensure that the gear control lever is in neutral position: position N for the handlebar
version, central lever position for the steering wheel version.
3 Vehicle use
THIS PRELIMINARY OPERATION IS NOT REQUIRED IN THE STEERING WHEEL

DIESEL VERSION.
18
Engine start up (03_05, 03_06)
3 Vehicle use
Engine ignition (gasoline version)
Open the fuel cock «A» (turn it counter clockwise to open and clockwise to close).
With cold engine, pull the starter lever «C» and insert the start key into the key switch,
then turn it to position 2 and at the same time press the accelerator control.
After start up, release the key that will automatically return to position 1.
WARNING
03_05
EXHAUST GASES ARE TOXIC. DO NOT START THE ENGINE IN A CLOSED

PLACE.
WHEN THE ENGINE IS ON, DO NOT HANDLE PARTS AND CONNECTIONS OF

THE ELECTRIC SYSTEM, ESPECIALLY THE SPARK PLUG CABLE.
03_06

Engine ignition (diesel version)
Introduce the start key into the switch and move it to position 1. On the instrument
panel, the glow plug preheat indicator will light up. The hotter the engine, the sooner
the indicator will turn off. Then move the key to position 2 while pressing the acceler-
ator control at the same time. After start up, release the key that will automatically
return to position 1.
03_07
19
WARNING

PLACE.

Starting off (versions with handlebar)
With idle engine, pull the clutch lever «A» and turn the gear knob to the 1st gear
(position 1 on the gear indicator «B »). To start off, release the clutch lever «A»
smoothly and accelerate by turning the throttle twist grip «C».
WARNING
03_08
PLACE.

Start-up (handlebar versions)
With idle engine, press the clutch pedal «A» and engage the first gear with the gearbox
lever. Gently release the clutch pedal while gradually pressing the accelerator pedal
«B».
3 Vehicle use
03_09
20
3 Vehicle use
Stopping the engine
Stopping the engine (handlebar)
Before stopping the engine, shift to neutral (position «N» on the gear indicator « B »).
Then turn the ignition key to «A».
Stopping the engine (steering wheel)

Before stopping the engine, move the gearbox to neutral (central position), then turn
the switch key to position «A».
Starting difficulties
Engine starting difficulties (gasoline version)
Possible causes and suggested actions:
- Carburettor flooded.
Close the fuel cock, turn the start key to position "1"; with closed starter open the gas
thoroughly and actuate the key switch, moving it to position "2"; open the fuel cock
again and move the key switch to position "2". In any case, do not try starting for more
than 5-6 times.
- Dynamotor or battery inefficiency.
Use an auxiliary battery with equivalent or slightly higher specifications with respect
to the original battery.
If you need to bump start the vehicle (by pushing or towing), follow these instructions:
engage a high gear (2nd or 3rd), do not exceed 20 kph (even when freewheeling),
release the clutch pedal or lever gradually.
21
Before performing this operation, check the reverse lever position. If you cannot start
the engine even with the procedure described above, contact an Authorised PIAG-
GIO Service Centre.
CAUTION
NEVER STRESS THE ENGINE AT LOW TEMPERATURES IN ORDER TO AVOID

POSSIBLE DAMAGE. WHEN DRIVING DOWNHILL, DO NOT EXCEED TOP
SPEED OR THE ENGINE COULD BE DAMAGED BY PROLONGED OVERREV-
VING.
CAUTION
• AFTER A LONG JOURNEY ALLOW THE ENGINE TO RUN AT IDLE

SPEED FOR A FEW SECONDS BEFORE SWITCHING IT OFF.
Gear position (03_10, 03_11, 03_12)

To reverse the vehicle, proceed as follows:
1. Stop the vehicle completely and turn the gear selector to neutral (position «N» on
the gear indicator «B») while the engine is idling;
2. For gasoline versions, lift the reverse gear control lever from position «A» to position
«B».
3. Diesel versions are not equipped with a reverse gear control lever.
3 Vehicle use
03_10 4. Use the gear control lever to engage gears; («1stgear» for the gasoline version,
«R» for the handlebar version), and gently release the clutch pedal while gradually
pressing the accelerator pedal.
22
5. To shift from reverse gear to the forward gears repeat the previously described
3 Vehicle use
procedures and move the reverse gear control lever to the «A» position (in the gas-
oline version and in the handlebar version).
Note: in the diesel handlebar version, once the reverse gear control lever has been
moved to the «B» position, both the reverse gear and the «1st gear» can be used for
vehicle parking manoeuvring; engagement of higher gears remains disabled until the
reverse gear control lever is set to the «A» position.
03_11
03_12
Driving Tips
Follow these simple recommendations to use your vehicle every day, confidently and
safely.
Your ability and your mechanical knowledge form the basis of safe riding. Practice
driving in a traffic-free area until you acquire a good knowledge of the vehicle.
1. Always drive within the limits of your ability, strictly following the road regulations of
the country where you are driving.
23
2. Carefully adjust the position of rear-view mirrors, to easily check the road behind
you.
3. Ensure nothing hinders the pedals stroke (mats, etc.)
4. Ensure that headlights are working properly.
5. To start the vehicle, with idle engine, engage the first gear and gently release the
clutch lever, accelerating at the same time.
6. Reduce speed on badly surfaced roads and drive with caution.
7. Do not brake fully on wet, unsurfaced or slippery roads.
8. Do not shift down when the engine is running at high revs to avoid dangerous over-
revving.
9. On a downhill, do not keep the gearbox to neutral position or the engine off, but
decrease speed closing the accelerator. To facilitate the decrease of speed, use the
brakes without pulling them for too long, to prevent dangerous overheating that would
decrease their efficiency. Shift down to increase the engine brake effect.
10. For rapid pick-up, e.g. for overtaking, shift down a gear to employ all the required
power.
11. When driving up demanding slopes, shift down to employ all the required power.
12. Check that the load is evenly distributed on the loading body, and do not exceed
the provided loads (see chapter: "Technical data -performance") to prevent tilting while
turning on a corner.
ALWAYS DRIVE YOUR VEHICLE WITHIN THE LIMITS OF YOUR ABILITY. DRIV-
ING WHILE DRUNK OR UNDER THE EFFECT OF DRUGS OR CERTAIN MEDI-
CINES IS EXTREMELY DANGEROUS AND INFRINGES THE ROAD REGULA-
3 Vehicle use
TIONS.
24
3 Vehicle use
ANY CHANGES TO VEHICLE PERFORMANCE, AS WELL AS ALTERATIONS TO
ORIGINAL STRUCTURE PARTS, RENDERS THE VEHICLE NO LONGER CON-
FORMING TO THE APPROVED TYPE AND THEREFORE DANGEROUS FOR
DRIVING SAFELY.
25
3 Vehicle use
26
Chap. 04
Doors and locks
27
Keys (04_01)
The vehicle is supplied with two copies of the key.
«A»: key for the ignition and start-up switch, the door lock and the fuel tank cover.
The code numbers, in fact, are the only way to identify the key for future copies.
YOU SHOULD KEEP A DUPLICATED KEY AND ITS CORRESPONDING CODE IN
ANY PLACE OTHER THAN THE VEHICLE.
04_01
Door locking/unlocking by key (04_02, 04_03)

The doors are provided with antitheft device. To open turn the key clockwise and press
button «A». To close turn the key anticlockwise.
04_02
4 Doors and locks
28
4 Doors and locks
To open both doors from the inside, use the special release control «B».
For the handlebar version, the release control «B» must be lifted, while for the steering
wheel version it must be pushed rightwards.
MAKE SURE IT IS SAFE TO OPEN THE DOORS BEFORE OPENING THEM. BE-
FORE STARTING OFF, MAKE SURE THE DOORS ARE CLOSED AND LOCKED.
THIS PRECAUTION WILL ENSURE THEY DO NOT OPEN ACCIDENTALLY
WHICH WOULD BE A HAZARD FOR THE DRIVER
04_03
Front door windows (04_04)

To open the windows, press the release lever while moving the handle downwards.
(7 fixed positions are available).
To close the windows, move the handle to "travel end top" position.
04_04
29
Engine inspection port (04_05)
Lower the rear side board and grip the handle «A» pulling it upwards to release the
retain clips «B».
On the vehicles with loading body in light alloy with tilting, to access the engine com-
partment it is necessary to lower the side and rear boards and then tilt the loading
body.
Use the special safety bar to secure the loading body in tilted position.
NEVER WORK UNDERNEATH THE LOADING BODY WHEN IT IS TILTED WITH-
04_05 OUT HAVING FIRST SECURED THE SAFETY BAR. DANGER OF SERIOUS IN-
JURY.
4 Doors and locks
30
Chap. 05
Seats and safety
belts
31
Using the safety belts
Observe the following suggestions for using the seat belts correctly. Failure to follow
these instructions may lead to severe injury in the event of an accident or sudden
braking. Check the seat belts periodically to ensure proper functioning. If its operation
appears faulty, have it checked at an Authorised PIAGGIO Service Centre imme-
diately.
Pregnant women: PIAGGIO recommends using the seat belt. The waist height seat
belt length should adhere snugly to your body as low as possible (on the hips) and not
at your waist. Ask your doctor for advice.
Injured people: PIAGGIO recommends using the seat belt. Ask your doctor for ad-
vice.
WARNING
THE SAFETY BELTS ARE DESIGNED TO EXERT THEIR ACTION ON THE BONE
STRUCTURE OF YOUR BODY. THE DIFFERENT BELT SECTIONS SHOULD FIT
SNUGLY TO THE PELVIS, THE CHEST AND SHOULDERS. DO NOT WEAR THE
SECTION WHICH IS SUPPOSED TO FIT ON THE HIPS OVER THE ABDOMEN.
SAFETY BELTS SHOULD BE ADJUSTED TO FIT SNUGLY AND SHOULD BE
ADAPTED TO THE PERSON WEARING THEM, SO AS TO OFFER THE PROTEC-
TION THEY ARE DESIGNED FOR. A LOOSE BELT WOULD CONSIDERABLY
REDUCE PROTECTION TO THE PASSENGER WEARING IT. BE CAREFUL NOT
TO DAMAGE BELTS WHEN CLOSING THE DOORS. DO NOT REMOVE BELTS
5 Seats and safety belts
FOR CLEANING. WASH THEM WITH WATER AND NEUTRAL SOAP, RINSE AND
LET DRY IN A WARM PLACE. PAY SPECIAL ATTENTION NOT TO DAMAGE THE
SEAT BELTS WITH CLEANING PRODUCTS, OIL, ABRASIVE DETERGENTS,
CHEMICAL AGENTS OR BATTERY FLUIDS
.
32
WARNING

AFTER A SEVERE ACCIDENT, IT IS ESSENTIAL TO HAVE THE ENTIRE SEAT
BELT ASSEMBLY REPLACED, EVEN IF IT MAY NOT APPEAR DAMAGED. DO
NOT WEAR A TWISTED SEAT BELT. DO NOT WEAR THE SEAT BELT WITH THE
SHOULDER LENGTH UNDER YOUR ARM OR BEHIND YOUR BACK. DO NOT
FASTEN THE SEAT BELT OVER HARD OR FRAGILE OBJECTS, SUCH AS
GLASSES, JEWELLERY, PENS, KEYS. DO NOT WEAR THE SEAT BELT OVER
VERY THICK CLOTHES, AS THIS MAY PREVENT IT FROM BEING POSITIONED
CORRECTLY. DO NOT MODIFY OR DISASSEMBLE THE SEAT BELT ASSEM-
BLY. AFTER AN ACCIDENT OF A CERTAIN SEVERITY, WE RECOMMEND THAT
YOU HAVE THE SEAT BELT WHICH WAS BEING WORN REPLACED AT AN AU-
THORISED PIAGGIO SERVICE CENTRE, EVEN IF IT DOES NOT APPEAR DAM-
AGED.
Fasting the safety belt (05_01)

Take the metal tongue from its housing.
Insert the metal tongue in the buckle until it clicks.
CAUTION
TO GUARANTEE THE OPTIMAL PERFORMANCE OF THE SEAT BELT, AFTER

05_01 HAVING INSERTED THE METAL TONGUE INTO THE BUCKLE, CHECK IT IS SE-
CURELY BLOCKED AND THE SEAT BELT IS NOT TWISTED.
33
Adjusting the safety belt (05_02)
Position the seat belt as low as possible on your hips and not at your waist.
Adjust the seat belt so that you can slide your fist between the belt and your chest.
Hold the anchoring at a right angle with respect to the belt and pull the belt to lengthen
or shorten it.
A: wrong
B: right
05_02
To release the safety belt (05_03)

Press the button. Insert the metal tongue in its housing when it is not in use.
CAUTION
TO PREVENT DAMAGING SEAT BELTS CHECK THEY DO NOT REMAIN
PINCHED BETWEEN A DOOR AND THE CAR BODY, OR BEHIND THE SEAT
BACK.
05_03
34
Chap. 06
Instrument panel
and controls
35
Handlebars (06_01)
Apetm
1. External light control switch
2. Tachometer and odometer
3. Ashtray
4. Gear indicator
5. Clutch lever
6. Cigar lighter
7. Turn indicator selector
8. Reverse gear command lever
9. Key switch
10. Emergency or parking brake
11. Heater control lever (red)
12. Starter lever (only in the gasoline version)
6 Instrument panel and controls
13. Brake pedal

14. Headlight switch
15. Horn button
16. Accelerator control
17. Light indicators unit
18. Emergency light switch
19. Rear fog light switch
20. Windscreen wiper control switch
36
06_01
Handlebars (06_01, 06_02)

ApetmD
3. Ashtray
4. Gear indicator
5. Clutch lever
6. Cigar lighter
37
7. Turn indicator selector
8. Reverse gear command lever
9. Key switch
11. Heater control lever (red)
12. Airflow deflector lever: windscreen - floor heating
13. Brake pedal
14. Headlight switch
15. Horn button
16. Accelerator control
18. Heater fan switch
20. Windscreen wiper control switch.
22. Body tilting button (where available).
38
06_02
Steering wheel (06_03)

Apetm
1. Steering wheel
2. Flashing light switch lever
3. Light and horn switch lever
4. Key switch
5. Clutch pedal
6. Brake pedal
39
7. Accelerator pedal
10. Reverse gear control lever
11. Gearbox control lever
13. Heating control lever (red)
14. Starter lever (only gasoline version) (black)
16. Cigar lighter
18. Ashtray
40
06_03
Steering wheel (06_03, 06_04)

ApetmD
1. Steering wheel
2. Flashing light switch lever
3. Light and horn switch lever
4. Key switch
5. Clutch pedal
6. Brake pedal
41
7. Accelerator pedal
10. Reverse gear control lever
11. Gearbox control lever
13. Heating control lever (red)
14. Airflow deflector lever: windscreen - floor heating
16. Cigar lighter
17. Heater fan switch
18. Ashtray
22. Body tilting button (where available).
42
06_04
Controls (06_05, 06_06, 06_07, 06_08, 06_09)

HANDLEBAR VERSION - GASOLINE
External light control switch «A»
0 = Lights off;
1 = Front and rear side/taillights and instrument panel lights on;
2 = Headlights (high or dipped beams on).
43
Windscreen wiper control switch «B»
0 = Disabled;
1 = Windscreen wiper enabled.
2 = Windscreen wiper + sprayer enabled.
06_05
Light selector «A»

1 = High beams on.
2 = Dipped beams;
THE SWITCH POSITIONS ARE SUBJECT TO THE OUTSIDE LIGHT CONTROL
SWITCH POSITION.
Horn button
B = horn button.
06_06
44
Turn indicator selector «C»
0 = Lights off;
S = Left turn indicators flashing;
D = Right turn indicators flashing.
06_07
Emergency light switch «B»

0 = Lights off;
1 = Direction indicators flashing
Rear fog light switch «A»

0 = Light off;
1 = Rear fog light on.
06_08
STEERING WHEEL VERSION - GASOLINE

Light and horn switch lever «A»
With external light control switch «B» in position enabled.
45
1 = Taillights on;
2 = Dipped beams on;
3 = High beams on.
To actuate the horn, press lever «A» upwards.
THE LIGHT SWITCH LEVER POSITIONS ARE SUBJECT TO THE OUTSIDE LIGHT
CONTROL SWITCH POSITION.
Flashing light switch lever «C»

0 = Lights off;

0 = Lights off;
1 = Lights on.

0 = Disabled;
Rear fog light switch «C»

0 = Light off;
46

Emergency light switch «D»
0 = Lights off;
Cigar lighter«E»
Press the lighter button and wait until it automatically returns to its initial position. The
lighter is ready for use.
06_09
Controls (06_09, 06_10, 06_11, 06_12, 06_13, 06_14)

HANDLEBAR VERSION - DIESEL
0 = Lights off;
1 = Front and rear side/taillights and instrument panel lights on;
2 = Headlights (high or dipped beams on).
47
0 = Disabled;
06_10
Light selector «A»

1 = High beams on.
2 = Dipped beams;
THE SWITCH POSITIONS ARE SUBJECT TO THE OUTSIDE LIGHT CONTROL
SWITCH POSITION.
Horn button
B = horn button.
06_11
48
Turn indicator selector «C»
0 = Lights off;
06_12
Rear fog light switch «A»

0 = Light off;
Heater fan switch «B»

0 = Fan off
1 = First gear
2 = Second gear
Emergency light switch «A»

0 = Lights off;
49
Body tilting button «B» (where available)
0 = Body down
1 = Body up
In order to improve safety and prevent unintentional operations, the lifting controls only
becomes live after releasing the safety lever on the right hand side at the back of the
cabin.
Remember to bring the safety lever back onto the 'blocked' position once all tilting
operations are completed.
06_13
• THE BODY LIFTING OPERATIONS MUST BE CARRIED OUT WITH THE
VEHICLE STOPPED AND THE EMERGENCY/PARKING BRAKE ACTI-
VATED.
STEERING WHEEL VERSION - DIESEL

Light and horn switch lever «A»
With external light control switch «B» in position enabled.
1 = Taillights on;
2 = Dipped beams on;
3 = High beams on.

To actuate the horn, press lever «A» upwards.
THE LIGHT SWITCH LEVER POSITIONS ARE SUBJECT TO THE OUTSIDE LIGHT
CONTROL SWITCH POSITION.
Flashing light switch lever «C»

0 = Lights off;
50

0 = Lights off;
1 = Lights on.

0 = Disabled;
Rear fog light switch «C»

0 = Light off;
Heater fan switch «D»

0 = Fan off
1 = First gear
2 = Second gear
51
Cigar lighter«E»
Press the lighter button and wait until it automatically returns to its initial position. The
lighter is ready for use.
06_14
Emergency light switch «F»

0 = Lights off;
1 = Emergency light on.
Body tilting button «G»

0 = Body down
1 = Body up
52
In order to improve safety and prevent unintentional operations, the lifting control only
cabin.
• TIPPING ACTIONS OF THE PLATFORM MUST BE CARRIED OUT WHEN
THE VEHICLE IS STOPPED AND THE HANDBRAKE ENGAGED.
06_15
Ignition switch (06_16, 06_17)

According to the version (steering wheel or handlebar), the key switch is on the left of
the steering wheel or on the front side, on the steering column cover.
The key can turn to 3 different positions:
0 = Ignition off, key can be removed, steering locked.
1 = Running position - arrangement of utilities and external lights and start up of pre-
heating glow plug (for diesel versions).
06_16 2 = Engine start up (after start up, the key automatically returns to the running position
"1").
Locking the steering (antitheft): with the key switch set to 0, extract the key and turn
the steering wheel leftwards (travel end).
Unlocking the steering: insert the key and turn it to 1.
Steering wheel lock (antitheft): with the key switch set to 0, extract the key and turn
the steering wheel to lock it.
Steering wheel release: insert the key and turn it to 1.
53
DO NOT TURN THE KEY TO POSITION 0 WHILE DRIVING.
WARNING
SHOULD THE STARTING DEVICE BE TAMPERED WITH (E.G. A THEFT AT-

06_17 TEMPT) HAVE IT CHECKED AT THE EARLIEST OPPORTUNITY BY A DEALER
OR AN AUTHORISED PIAGGIO SERVICE CENTRE BEFORE YOU START DRIV-
ING AGAIN.
WHEN YOU LEAVE THE VEHICLE, ALWAYS REMOVE THE KEY TO PREVENT
SOMEBODY FROM ACCIDENTALLY ACTUATING THE CONTROLS. ENGAGE
THE PARKING BRAKE AND THE FIRST OR REVERSE GEAR ACCORDING TO
WHETHER THE VEHICLE IS UPHILL OR DOWNHILL. SUITABLY TURN THE
STEERING WHEEL TO PREVENT BLOCKING THE ROAD IN CASE OF AN AC-
CIDENTAL RELEASE OF THE EMERGENCY OR PARKING BRAKES.
54
Chap. 07
Gauges and
Warning Lights
55
Instrument unit and indicators (07_01)
A = Speedometer, odometer/mileometre.
B = Preheat glow plug indicator (only on diesel versions - amber colour).
C = Flashing lights on indicator (green colour).
D = High beams on indicator (blue colour).
E = Taillights on indicator (green colour).
F = Rear fog light on indicator (amber colour).
07_01
G = High water temperature indicator (only on diesel versions - red colour).
H = Oil reserve indicator (for gasoline versions). Inadequate oil pressure indicator (for
diesel versions).
I = Fuel reserve indicator (amber colour).
L = Battery charge voltage low indicator (red colour).
7 Gauges and Warning Lights
56
Chap. 08
Air control
system
57
Heating (08_01)
Cabin heater controls (gasoline):
Lever «A» (with red grip): in position 1.
Control bar «B»: in position 1 (travel end back) located below the driver's seat to allow
opening diaphragm «C».
Shuttering outlets «D» in position 1 (OPEN).
The cabin heater can be disabled by the shuttering outlets «D» or directly by returning
08_01 lever «A» to neutral position (position 2).
Heating (08_01, 08_02)

Cabin heating controls (diesel):
Lever «A» (with red grip): position 1, warm air.
Lever «B»: position 1, warm air towards feet.
Lever «B»: position 2, warm air towards the windscreen.
08_02
8 Air control system
58
Heating and demisting (08_03)

Cabin defrosting/heating controls (gasoline):
Control bar «B» in position 2 (travel end forward).
Shuttering outlets «D» in position 1 (OPEN).
08_03
Heating and demisting (08_03, 08_04)

Cabin defrosting/heating controls (diesel):
Control bar «B» in position 2.
08_04
Demisting (08_05)
Cabin defrosting controls (gasoline):
Control bar «B» in position 2 (travel end forward).
Shuttering outlets «D» in position 2 (CLOSED).
The hot air flow is thus sent to the windscreen only, through the two outlets shown in
the figure.
08_05
59
Demisting (08_05, 08_06)
Cabin heating controls (diesel):
Control lever «B» in position 1.
The hot air flow may be partitioned through the two outlets «D».
08_06
60
Chap. 09
Mirrors and
Window Glasses
61
Adjusting the mirror (9_01)
Rear-view mirrors are adjusted by moving the mirror body manually until the ideal
angle is obtained to guarantee full visibility.
CAUTION
NEVER ADJUST MIRRORS WHILE DRIVING AS YOU MAY LOSE CONTROL OF

THE VEHICLE.
9_01
Wipers and Brushes (9_02, 9_03)

Blade
• Clean regularly the rubber part with specific products.
• Replace the blade if the rubber is misshapen or worn. In any case, blades
should be replaced approximately once a year.
Some simple recommendations can minimise the possibility of damage to the blade:
9 Mirrors and Window Glasses
• - If the temperature is below zero, make sure the rubber part is not frozen to
the windscreen. If required, use a de-icing product to release the blade.
• - Remove any snow from the windscreen: this will protect the blade and avoid
overloading and overheating the electric motor.
• Do not operate the windscreen wiper on a dry windscreen.
DRIVING WITH A WORN WINDSCREEN WIPER BLADE CAN BE EXTREMELY

DANGEROUS AS VISIBILITY IS DECREASED IN POOR WEATHER CONDITIONS.
62
Replacing the windscreen wiper blade
Replace the windscreen wiper blade as follows:
• Lift the windscreen wiper arm "A" and position the blade so that it forms a
right angle with the arm;
• Press retainer tab "B" of the latching spring and extract the blade for arm
"A";
• Fit a new blade. Insert the tab in its seat on the arm. Make sure it is locked.
9_02
Nozzles
• If there is no jet of fluid, first of all check whether the windscreen washer
reservoir is full.
• Check whether the holes «A» are clogged. If so, open them with a pin.
• Direct the windscreen washer nozzles so that the jets are directed towards
the highest position of the blade stroke.
9_03
63
64
Chap. 10
Inside
equipment
65
10 Inside equipment
66
Chap. 11
Electrical
system
67
Fuel version
The power for the lighting and indication system devices is provided in direct current
by a dynamotor/battery unit, with a voltage regulator separated by the remote control
switch unit, both installed under the seat in the compartment. The dynamotor acts as
a generator-dynamo and as a starter motor: in particular, upon start-up, it absorbs
current from the battery and operates as an electric motor.
After starting the engine and reaching a certain speed, the dynamotor acts as a normal
dynamo, charging the battery and powering the vehicle system.
Electric characteristic
Battery
12V-32Ah
Diesel version
The power for the lighting and indication system devices is provided in direct current
by a special battery.
The engine is equipped with an 18-pole rotor stator unit, three-phase, 330W MAX.
The preheating device for starting the engine, which is fitted with a light indicator,
controls the special preheat glow plug.
FOR ESPECIALLY COLD AREAS, WE RECOMMEND INSTALLING A 12V-60AH
BATTERY.
11 Electrical system
WHEN INTERVENING ON THE ELECTRICAL SYSTEM, MAKE ESPECIALLY

SURE THAT THE WIRES LEADING TO THE ELECTRONIC CONTROL UNIT ARE
CORRECTLY CONNECTED AND RESPECT THE COLOUR CODING GIVEN ON
THE CONTROL UNIT.
Electric characteristic
Battery
68
69
12V-50Ah
70
Chap. 12
Emergency
71
Wheel replacement (12_01, 12_02)
The tyre replacement operation and the use of jack require some precautions which
are given below.
WARNING
SIGNAL THE PRESENCE OF THE VEHICLE AS PRESCRIBED BY THE HIGHWAY

CODE IN FORCE.
12_01
PLACE THE JACK IN THE POSITIONS SHOWN SO AS NOT TO DAMAGE ME-
CHANICAL PARTS OR THE BODY
WARNING
WHENEVER POSSIBLE, REPLACE TYRES WITH THE VEHICLE ON LEVEL

GROUND. IF THE GROUND IS SLOPING OR BADLY SURFACED, PUT WEDGES
OR ANY OTHER SUITABLE MATERIAL UNDER THE WHEELS TO BLOCK THE
VEHICLE. DO NOT GREASE BOLT THREADS BEFORE REFITTING: THEY
12_02 COULD COME UNDONE SPONTANEOUSLY.
NEVER TAMPER WITH THE INFLATION VALVE. DO NOT PLACE TOOLS BE-
TWEEN RIM AND TYRE.
Maintenance instructions
12 Emergency
They are located into the compartment, below the seat.
72
CAUTION
12 Emergency
THE JACK CAN ONLY BE USED TO REPLACE THE WHEELS. NEVER USE THE
JACK TO PERFORM REPAIRS UNDER THE VEHICLE. THE VEHICLE MAY FALL
IF THE JACK IS NOT POSITIONED CORRECTLY
CAUTION
PERIODICALLY CHECK TYRE PRESSURE ACCORDING TO THE VALUES GIV-

EN IN THE: «MAINTENANCE
».
73
12 Emergency
74
Chap. 13
Maintenance
75
Check engine oil level (13_01)
Engine oil level check (diesel version)
To check the engine oil level, proceed as follows:
1. Check with engine off and vehicle on a flat surface;
2. Extract the level bar from the rear side of the vehicle and check that the level is
between the MIN and MAX positions;
3. If a top up is required, add new oil by the filler located into the engine compartment;
13_01 WARNING
TOP UP USING OIL OF THE SAME TYPE ALREADY CONTAINED INTO THE EN-
GINE.
Oil change and oil filter replacement (13_02, 13_03, 13_04)

Replacing the engine oil (diesel version)
To replace the engine oil proceed as follows:
1. Loosen the drainage cap «A» and drain the oil;
2. When drainage is complete, tighten cap «A», remove cap «B» and pour new oil by
the filler; the oil level must always be between the MIN and MAX positions marked on
bar «C»;
13 Maintenance
13_02 3. Periodically check the oil level;
76
WARNING
13 Maintenance
REPLACE THE OIL WHEN THE ENGINE IS WARM.
CAUTION
13_03 RUNNING THE ENGINE WITH INSUFFICIENT LUBRICATION OR IMPROPER LU-

BRICANTS ACCELERATES THE WEAR OF ALL MOVING PARTS AND MAY
RESULT IN SERIOUS DAMAGES.
CAUTION
USED OIL IS HARMFUL TO THE ENVIRONMENT. WHEN REPLACING THE OIL,

WE SUGGEST TO CONTACT A PIAGGIO AUTHORISED SERVICE POINTS
EQUIPPED FOR DISPOSING SPENT OILS IN THE RESPECT OF NATURE AND
IN COMPLIANCE WITH THE LAWS IN FORCE.
13_04
Characteristic
new oil:
2.8 litres
77
Oil change and oil filter replacement (13_04, 13_05)
Engine oil cartridge replacement (Diesel version)
To gain access to the oil cartridge proceed as follows:
1. Remove the engine inspection door (or lift the metal alloy plate);
2. Drain the engine crankcase;
3. Remove the filtering body «F»;
4. Lubricate the new cartridge seal and screw it in as far as it will go, and then tighten
13_05 it by hand by half a turn;
5. Fill up with fresh oil, then start the engine whilst inspecting for oil leaks.
WARNING
TO PREVENT DAMAGING THE ENGINE, FILL THE FILTER WITH NEW OIL BE-
FORE PROCEEDING TO THE REASSEMBLY.
IN CASE OF REPLACEMENT OF THE FILTER, THE AMOUNT OF OIL CON-
TAINED INTO THE CRANKCASE IS OF ABOUT 2.8 LITRES (THE TOTAL CIRCUIT
CAPACITY IS 3.5 LITRES).
WARNING
USING NON-ORIGINAL SPARES SERIOUSLY IMPAIRS THE VEHICLE PER-

FORMANCE AND LIFE.
13 Maintenance
78
WARNING
13 Maintenance
TO DISPOSE OF OLD FILTERS, TURN TO A PIAGGIO SERVICE CENTRE. FOL-
LOW THE SPECIFIC ENVIRONMENT-RELATED REGULATIONS IN FORCE.
Checking the brake fluid level (13_06)

Checking level (gasoline version)
The rear brake fluid tank is located into the driver compartment, above the brake pedal.
Check the level as follows:
1. Stop the vehicle on level ground;
2. Check the oil level is between 1 cm under the surface of cap «A» (MAX level) and
1 cm over the bottom of the reservoir (MIN level).
13_06 If the oil is under the minimum level contact a PIAGGIO Dealer or Authorised Service
Centre to have the brake system checked.
Topping up brake fluid

To fill the reservoir, unscrew cap «A» and top up.
In normal climates, replace the fluid every 20,000 km or every 2 years.
Qualified and skilled personnel is required for this operation. We recommend you go
to a PIAGGIO Dealer or Authorised Service Centre.
AGIP DOT4 BRAKE FLUID
Brake fluid
79
FMVSS DOT 4
Checking the brake fluid level (13_06, 13_07)

Level check (Diesel version)
The rear brake fluid reservoir is located inside the vehicle, underneath the cover on
the right-hand side of the instrument panel.
To check the level, remove the two fixing screws and the cover, then follow the pro-
cedure outlined in the previous paragraph.
CAUTION
13_07
ONLY USE DOT 4 CLASSIFIED BRAKE FLUIDS.

CAUTION
BRAKE FLUID IS HAZARDOUS: WASH WITH WATER IN THE EVENT OF ACCI-

DENTAL CONTACT.
CAUTION
BRAKING CIRCUIT FLUID IS VERY CORROSIVE; AVOID CONTACT WITH PAIN-

13 Maintenance
TED PARTS.
THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC, I.E., IT ABSORBS HUMIDITY

FROM THE SURROUNDING AIR. IF THE HUMIDITY IN THE BRAKE FLUID EX-
80
13 Maintenance
CEEDS A CERTAIN VALUE, IT WILL LEAD TO INEFFICIENT BRAKING. NEVER
USE BRAKE FLUID FROM PREVIOUSLY OPENED OR PARTLY-EMPTY CON-
TAINERS.
Gear box oil level (13_08, 13_09, 13_10)

To check the gearbox oil, proceed as follows:
1. Check with engine off and vehicle on a flat surface;
2. Loosen the two screws fixing the SAS to the support bracket and move the SAS so
as to access the cap «A»;
3. Loosen the inspection cap «A», then check that the oil level is between the MIN
and MAX references on the bar contained into the cap;
13_08 4. If you need to top up the level, extract the cap with the bar and restore the level;
5. Replace the SAS to the original position.
TOP UP USING OIL OF THE SAME TYPE ALREADY CONTAINED INTO THE
GEARBOX.
13_09
81
To replace the gearbox oil proceed as follows:
1. Remove the cap «A», loosen cap «B» and drain the oil; when drainage is complete,
replace cap «B».
2. Pour some oil into the top hole and let the engine run for a few seconds; then, drain
the crankcase again.
3. Refill with new oil, periodically checking the level with the bar until the mark MAX
is reached.
WARNING
13_10
REPLACE THE OIL WHEN THE ENGINE IS WARM.

• AN EXCESSIVE AMOUNT OF OIL CAN SPILL OUT AND DIRTY THE EN-
GINE.
WARNING
• USED OIL CONTAINS SUBSTANCES HARMFUL TO THE ENVIRON-

MENT. FOR OIL REPLACEMENT, CONTACT ANY AUTHORISED PIAG-
GIO SERVICE CENTRE AS THEY ARE EQUIPPED WITH LAW-ABIDING
ENVIRONMENTALLY- FRIENDLY OIL DISPOSAL SYSTEMS
AGIP ROTRA MP 80W-90
13 Maintenance
Oil with specifications SAE 80W-90, API GL-5

Gearbox oil
Characteristic
Oil amount for gasoline version:
82
885 grams (approx. 1000 cm3)
13 Maintenance
Window washer fluid level (13_11)
Topping up windscreen washer fluid
The windscreen washer fluid reservoir is located inside the cab on the front right panel.
To fill the reservoir, unscrew cap «A» and top up. Use a specific detergent.
13_11
Cooled fluid (13_12)

Coolant top-ups (Diesel version)
Loosen the filler cap on the expansion tank.
Fill up the tank with coolant (permanent 50% water + ethyl glycol fluid recommended).
The correct level is indicated on the expansion tank by the LEVEL reference mark.
Circuit air-bleed: start the engine up and let it run at idle so to allow for any air bubble
trapped inside the circuit to leave the cooling system.
13_12 The coolant level will gradually decrease and then settle. Stop the engine and top-up
the circuit as explained in the previous paragraph. After a few hours of normal use,
check the level with the engine cold.
Cooling circuit hose inspection (every 10,000 Km)
83
Check the coolant circuit hoses for signs of wear (alligatoring of the rubber) and also
check that all fittings are properly sealed. If any of the hoses is worn, please contact
your nearest Authorised Piaggio Service Centre to have it replaced.
Changing the engine cooling fluid

Drain the circuit completely and refill following the procedure given in the previous
paragraphs.
Checking and replacing the air cleaner element (13_13, 13_14)

Replacing the air filter (gasoline version)
To replace the air filter, proceed as follows:
1. Lower the rear side and remove the engine cover;
2. Loosen the three knobs «A» fixing the filter cover, then remove the cover;
3. Remove the filtering element «B»;
4. Replace the filtering element and refit the cover.
13_13
13 Maintenance
13_14
84
Checking and replacing the air cleaner element (13_14, 13_15,
13 Maintenance
13_16)
Replacing the air filter (diesel version)
To replace the air filter, proceed as follows:
1. Loosen the fixing know «A» and remove the filter box cover «B»;
2. Extract the filtering element «C» and replace it with a new one;
3. Refit the cover and tighten the knob «A».
13_15
CAUTION
THE FILTERING ELEMENT MUST BE REPOSITIONED INSIDE THE AIR-BOX
PROPERLY, FOLLOWING THE REMOVAL OPERATIONS BUT IN REVERSE OR-
DER.
13_16
Replacing the fuel filter (13_17)

Replacing the diesel filter
The diesel filter «A» can be removed by turning it anticlockwise.
At the bottom of the cartridge there is the screw «B» for draining condensation water.
To drain the condensation water, loosen the screw «B»; tighten it again when diesel
without water comes out.
13_17
85
Air bleeding (13_18)
Bleed air once the injection system has been emptied for checking due to running out
of fuel.
To this purpose, repeatedly actuate the lever controlling the hand pump, until you feel
a resistance during the pumping phase.
Normally, a totally empty system is filled with about 40 pumping actions.
13_18
Fuel exhaustion (13_19)

Running out of fuel (diesel version)
If you run out of fuel, refuel and then actuate the lever controlling the hand pump, as
described for the air bleeding, until you feel a certain resistance during the pumping
phase.
Then, start the engine according to the standard procedure.
If you feel a certain resistance in the pumping and the stroke of the hand pump control
lever is not complete, turn the driving shaft by another revolution to return the mark
13_19 «D» at the reference «E».
Actuate the hand pump again until the injection system is totally bled.
N.B.
IN CASE OF AIR BLEEDING AND OF RUNNING OUT OF FUEL, IN ORDER TO
OBTAIN THE MAXIMUM CAPACITY OF THE HAND PUMP IT IS NECESSARY TO
13 Maintenance
TURN THE DRIVING SHAFT UNTIL THE MARK «D» PUNCHED ON THE CLUTCH
BOX MATCHES THE REFERENCE «E» (TDC) OF THE CRANKCASE.
86
Checking and replacing the pre-heating plugs (13_20)
13 Maintenance
Access the spark plugs as follows:
1. remove the plate releasing the three fixing clamps;
2. disconnect the high voltage wire cap «A» from the spark plug «B»;
3. remove the spark plug using the provided tool;
4. when refitting, place the spark plug in place at the correct slant and screw it by hand.
Use the tool for locking only;
13_20 5. insert cap «A» fully on the spark plug and refit the rear washer.
THE SPARK PLUG SHOULD BE REMOVED ONLY WHEN THE ENGINE IS COLD.
CHANGE THE SPARK PLUG EVERY 4,000 KM. USING SPARK PLUGS WITH
DIFFERENT VALUE WITH RESPECT TO THE PRESCRIPTIONS OR WITH IN-
CORRECT THREADING CAN SEVERELY DAMAGE THE ENGINE.
Characteristic
Recommended spark plugs:
BOSCH W3AC
CHAMPION RL78C
NGK BR8HS
87
Fuses (13_21, 13_22, 13_23)
The electrical system is protected by six 8A fuses located underneath the instrument
panel, to the left of the steering column.
To the left of the fuse-box are two fuses: 15A fuse «G» protecting the cigarette lighter,
and 15A fuse «I» guarding the heater fan.
Van versions are also fitted with an 8A fuse located underneath the right-hand side
seat and protecting the van lighting circuit.
The vehicle is also protected by the main fuse «H» located underneath the passenger
13_21 seat.
The function of general fuse «H» varies according to the version:

- Gasoline = 40 A Safeguarding all services with the exception of the start-up power
circuit.
- Diesel = 40 A Safeguarding the preheating and charging circuits.
Next to the main fuse, on the tipper version, is an additional 80A fuse safeguarding
the body tilting system.
The six 8 A fuses safeguard different circuits depending on the vehicle's version.
13_22
BEFORE REPLACING THE BLOWN FUSE, TRY TO ELIMINATE THE FAULT

THAT CAUSED IT TO BLOW. NEVER ATTEMPT TO REPLACE A FUSE USING A
DIFFERENT MATERIAL (I.E. A PIECE OF ELECTRIC WIRE) OR A HIGHER AMP
FUSE.
13 Maintenance
13_23
88
13 Maintenance
IF YOU WANT TO FIT ADDITIONAL UNITS ON THE VEHICLE (E.G. ADDITIONAL
LIGHTS) WE POINT OUT THAT INCORRECT DERIVATIONS ON THE ELECTRIC
CONNECTIONS MAY CAUSE DAMAGE TO THE INSTALLATION.
Handlebar gasoline version

A. Dipped beams (left and right), rear fog light circuit.
B. High beams (left and right), high beams indicator.
C. Emergency (key OFF), windscreen wiper, horn, glass bowl.
D. Emergency (key ON), flashing lights, indicator circuits (recharge, oil reserve, fuel
reserve, tilting), stop lights, reverse gear lights.
E. Instrument lighting, light indicator, number plate lighting, taillights (left rear and
front), cigar lighter lighting.
F. Taillights (right rear and front).
Steering wheel gasoline version

A. Emergency (key OFF), windscreen wiper, horn, glass bowl.
B. Emergency (key ON), flashing lights, indicator circuits (recharge, oil reserve, fuel
reserve, tilting), stop lights, reverse gear lights.
C. Right dipped beam.
D. Left dipped beam, rear fog light circuit.
front), cigar lighter lighting.
89
Handlebar diesel version
A. Emergency (key OFF), windscreen wiper, horn, glass bowl.
B. Emergency (key ON), flashing lights, indicator circuits (recharge, oil pressure, oil
temperature, fuel reserve, preheating, tilting), stop lights, reverse gear lights, solenoid
valve, preheating (power circuit excluded).
C. Right dipped beam.
D. Left dipped beam, rear fog light circuit.
front), cigarette lighter lighting.
Handlebar diesel version

A. Dipped beams (left and right), rear fog light circuit.
B. High beams (left and right), high beams indicator.
C. Emergency (key OFF), windscreen wiper, horn, glass bowl.
D. Emergency (key ON), flashing lights, indicator circuits (recharge, oil pressure, oil
temperature, fuel reserve, tilting, preheating), stop lights, reverse gear lights.
front), cigarette lighter lighting.
13 Maintenance
90
Exhaust circulation system (EGR) (13_24)
13 Maintenance
Secondary air box - SAS (gasoline version)
Remove the two screws «A» of the aluminium SAS cover, without extracting the metal
pipe from the cover/sleeve. Remove the plastic cover and the plate, pull the sponge
out and wash with soap and water.
Dry with compressed air before reassembling. Reinstall the plate into the seat on the
two plastic and aluminium covers.
Replace the box sealing O-Ring housed in the cover seat at every disassembly.
13_24
TURN TO AN AUTHORISED PIAGGIO SERVICE CENTRE FOR THIS OPERA-

TION.
Tyres (13_25)
• Periodically check the inflation pressure of each tyre.

• Tyres feature wear indicators; replace tyres as soon as these indicators be-
come visible on the tyre tread.
• Also check that there are no cuts on the sides of the tyres or irregular tread
wear; in such cases, contact an authorised service centre for the replace-
ment.
Characteristic
13_25 TYRES
4.50 - 10''
91
TYRE PRESSURE
Pressure
ACCORDING TO THE PROVISIONS OF THE REGULATIONS IN FORCE, THE

TYRE TREADS MUST BE OVER 1.6 MM THICK.
CHECK TYRE PRESSURE WHEN COLD. INCORRECT TYRE INFLATION PRES-

SURE WILL CAUSE UNEVEN THREAD WEAR AND MAKE DRIVING DANGER-
OUS.THE TYRE MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR
LIMITS SET FORTH BY LAW.
Periods of inactivity
Prolonged inactivity
If the vehicle is not to be used for long periods, the battery must be charged periodically
(when not in use, the battery will discharge over a period of about three months). If
the battery is removed, make sure you connect the leads correctly at the time of in-
stallation
13 Maintenance
Perform the following operations:

1. Clean the vehicle;
92
2. Remove the air filter and close the intake and exhaust ducts;
13 Maintenance
3. Lift the vehicle from the ground, resting the wheels on wooden supports;
4. Drain the fuel tank. Cover the unpainted metal parts with rustproof grease;
5. For the battery, follow the procedures indicated in the «Maintenance» section.
FOR THE GASOLINE VERSION WITH ENGINE ON AND AT LOW SPEED, POUR
30 CC OF SAE 40 OIL THROUGH THE CARBURETTOR CHOKE.
NO START-UP (GASOLINE VERSION)

Connectors to the spark plug Restore connection
disconnected
DIFFICULTIES WHEN STARTING (GASOLINE

VERSION)
Fuel tank empty Refuel
Clogged or dirty filters, jets or Contact an Authorised PIAGGIO

carburettor Service Centre
Starter control lever in lowered Move it to lifted position

position
93
DIFFICULTIES WHEN STARTING (DIESEL VERSION)
Connectors to the glow plug Restore the connection or replace
disconnected, or inefficient glow the preheating glow plug
plug
No fuel in tank Refuel
Air into the injection system Bleed the air
Water in the diesel Drain the water and replace the

filter, if required, then bleed the air
Injector dirty or faulty Contact an Authorised PIAGGIO

Service Centre
IGNITION FAILURE (GASOLINE VERSION)

No spark on spark plug Check whether the electrodes are
clean (clean with white spirit and
wire brush or sandpaper).
Check spark plug insulation: if
cracked or broken, replace the
spark plug. If the spark plug is in
good conditions, contact an
Authorised PIAGGIO Service
Centre.
13 Maintenance
CAUSE: HIGH VOLTAGE. THIS INSPECTION SHOULD BE

CARRIED OUT BY A SKILLED MECHANIC.
94
13 Maintenance
POOR COMPRESSION (GASOLINE VERSION)
Spark plug seat threading Contact an Authorised PIAGGIO
damaged; head bolts insufficiently Service Centre
torqued, piston seals worn
HIGH FUEL CONSUMPTION AND POOR

PERFORMANCE (GASOLINE VERSION)
Air filter blocked or dirty Replace the air filter
ENGINE IRREGULAR OPERATION (DIESEL VERSION)

Injector faulty Contact an Authorised PIAGGIO
Service Centre
Air into the injection system Bleed the air
Diesel filter clogged Replace the filter and bleed the air
POOR PERFORMANCE (DIESEL VERSION)

Service Centre
Diesel filter clogged Replace the filter and bleed the air
95
WHITE FUMES UPON EXHAUST (DIESEL VERSION)
Service Centre
Delayed injection Contact an Authorised PIAGGIO

Service Centre
BLACK FUMES UPON EXHAUST (DIESEL VERSION)

Air filter clogged Replace the air filter
Wrong injection pump calibration Contact an Authorised PIAGGIO

Service Centre

Service Centre
THE ENGINE KNOCKS

Injection advanced Contact an Authorised PIAGGIO
Service Centre

Service Centre
13 Maintenance
96
13 Maintenance
POOR SUSPENSION
Oil leaks or inadequate spring Contact an Authorised PIAGGIO
loading; stroke end bumpers worn. Service Centre
TRANSMISSION IS NOT SMOOTH

Gearbox failure Contact an Authorised PIAGGIO
Service Centre
Gearcase noise Contact an Authorised PIAGGIO

Service Centre
POOR BRAKING ACTION

Drums greasy, brake shoes worn Contact an Authorised PIAGGIO
Service Centre
Air into the circuit pipes Bleed the air
Shoe self-adjustment device faulty Contact an Authorised PIAGGIO

Service Centre
Irregular friction material wear Contact an Authorised PIAGGIO

Service Centre
Oil leaks from the circuit Contact an Authorised PIAGGIO

Service Centre
Air in the brake circuit Bleed the air Contact an

authorised PIAGGIO service
centre.
97
ELECTRIC SYSTEM INEFFICIENCY
Faulty controls (switches) or lights Contact an Authorised PIAGGIO
and indicators Service Centre
Battery inefficient Contact an Authorised PIAGGIO

Service Centre
Troubleshooting / What to do if... (13_26)

Idle adjustment
Adjust the idle speed as follows:
1. Release the three clamps and remove the plate.
2. Start the engine and take it to its normal operating temperature, i.e., 5 minutes run
at a medium speed.
3. Turn the gas valve travel end adjustment knob «A» to approach the minimum stop
13_26 limit of engine spontaneous stop.
4. Then, adjust the mixture flow adjustment screw «B» to reach the highest rpm num-
ber. If the rpm number reached is excessive, decrease it by knob «A» to reach a
regular minimum speed.
If this is problematic, go to a PIAGGIO Dealer or Authorised Service Centre.
13 Maintenance
THE IDLE ADJUSTMENT MUST BE PERFORMED WITH HOT ENGINE AND AC-
TIVE CATALYTIC CONVERTER. BEFORE PROCEEDING, CHECK THAT THERE
IS NO PLAY ON THE THROTTLE CONTROL. IF REQUIRED, GO TO A PIAGGIO
DEALER OR AUTHORISED SERVICE CENTRE TO HAVE THE THROTTLE CON-
TROL PLAY ADJUSTED.
98
CAUTION
13 Maintenance
IN CASE OF PROBLEMS WHEN ADJUSTING THE IDLE SPEED, IT MAY BE NEC-
ESSARY TO ADJUST EXHAUST EMISSIONS (CO). THIS OPERATION MUST BE
PERFORMED AT AN AUTHORISED PIAGGIO SERVICE CENTRE.
Characteristic
Idle adjustment
(approx. 1250 - 1450 rpm)
Troubleshooting / What to do if... (13_26, 13_27)

Brakes adjustment
The brake shoes are provided with a self-adjustment device that automatically re-
stores the proper clearance between blocks and drums, regardless of the friction
material wear, so it is not necessary to perform manual adjustments.
The brake drums are provided with hole with screw cap «A» through which it is pos-
sible to inspect the wear of the friction material: In case of excessive wear, replace
the brake shoes. For this operation, turn to a Concessionaire or to an Authorised
PIAGGIO Service Centre.
13_27

Parking brake
Pull the lever to engage parking brake. Lift the lever slightly to release the brake, press
the button with the thumb and lower the lever completely.
• BEFORE SETTING OFF ENSURE THE PARKING BRAKE IS FULLY RE-

LEASED AND THE WARNING LIGHT IS OFF. SHOULD THE PARKING
13_28 BRAKE BE PARTIALLY PULLED, THIS WOULD CAUSE THE BRAKES
99
TO OVERHEAT RESULTING IN LOSS OF BRAKING EFFICIENCY AND
EARLY WEAR OF THE FRICTION MATERIAL.
WHEN PARKING THE VEHICLE ON HILL ROADS, ALWAYS PULL THE PARKING
BRAKE LEVER FULLY AND MOVE INTO THE LOWEST GEAR OPPOSITE THE
DIRECTION FACED BY THE VEHICLE. IN ADDITION, POSITION WEDGES BE-
HIND THE WHEELS.
• TO IMPROVE SAFETY AND AVOID ACCIDENTAL ACTIVATIONS, WE

SUGGEST YOU ALWAYS PULL THE PARKING BRAKE BEFORE, OP-
ERATING THE LIFTING/LOWERING BODY CONTROL.

Air bleeding from the braking system
In case of anomalies of the brake performance, accompanied by idle pumping, have
the system drained by the Concessionaires or Authorised PIAGGIO Service Cen-
tres.
IN FACT, THE BRAKE FLUID IS HIGHLY CORROSIVE AND IT MUST BE DIS-
POSED ACCORDING TO PRECISE REGULATIONS. MOREOVER, ANY INTER-
VENTION TO THE BRAKING SYSTEM MUST BE CARRIED OUT ONLY BY
QUALIFIED PERSONNEL.
13_29
13 Maintenance
100
13 Maintenance
Brake pedal adjustment (steering wheel version)
Adjust the brake pedal stroke as follows:
1. Remove the nut «A» locking the adjustment screw «B».
2. Adjust the stroke by means of screw «B»;
3. Tighten the fastening nut «A».
For correct operation of the hydraulic brake system, the pedal should always have a
13_30 slight play on the brake cylinder.
BRAKING ACTION MUST START AT THE BEGINNING OF THE BRAKE LEVER

STROKE.
Troubleshooting / What to do if... (13_30, 13_31, 13_32)

Replacing the headlights
Replace the headlight bulb as follows:
1. Remove the headlight cover «A» turning it counter clockwise.
2. Release the two clips «B» fixing the lamp holders.
3. Extract the lamp holder «C» and replace the blown bulb «D».
4. Install the cover «A» inserting the 4 teeth «E» into the special slots and turn clock-
13_31 wise.
N.B.
TO REPLACE THE TAILLIGHT BULBS, FOLLOW THE INDICATIONS DESCRI-
BED FOR REPLACING THE HEADLIGHT BULB.
101
13_32

Front turn indicators
Replace the front turn indicator bulbs as follows:
1. Remove the plastic lens by removing the two screws «A»;
2. Extract the flashing light bulbs «B» pressing them and turning them clockwise.
13_33

Rear lights
To replace the turn indicator lights, the stop lights, the taillights, the reverse gear and
the rear fog light bulbs, proceed as follows:
13 Maintenance
1. Remove the plastic lens by removing the two screws «A»;

2. Extract the bulbs pressing them and turning them clockwise.
13_34
102
13 Maintenance
Number plate light
In order to remove the number plate light bulb, proceed as follows:
1. Remove the screw «A» fixing the bulb cover.
2. Replace the bulb and reassemble.
13_35

Front ceiling light
The cabin is provided with a courtesy light located above the internal rear-view mirror,
whose switch is located on the glass bowl.
To replace bulb «B», remove snap-on lens «A» by hand.
13_36
103
Troubleshooting / What to do if... (13_36, 13_37, 13_38)
Headlights adjustment
Proceed as follows:
1. Place the vehicle in conditions of use, without load, with the tyres inflated as pre-
scribed, on flat ground at 10 m from a white screen in the shade. Make sure the vehicle
axis is perpendicular to the screen;
2. Draw two vertical lines «a-a» at a distance «A» corresponding to the distance be-
tween headlight axes. Draw a horizontal line «b-b» at height «B» from ground
13_37 corresponding to the headlight centre height from ground multiplied by 0.9;
3. Start the engine and lock the throttle twist grip at approximately 1/3 of its travel.
Switch the dipped beam headlight on. Direct the beam so that the horizontal line be-
tween the light and the shade falls above the horizontal line «b-b» drawn on the
screen;
4. If this is not so, adjust the headlight by means of the two screws «A» to correct any
beam alterations.
CAUTION
13_38
THE ADJUSTMENT OF THE HEADLIGHTS ORIENTATION IS AN OPERATION
THAT, IF NOT PERFORMED PROPERLY, INFRINGES ON A SPECIFIC RULE OF
THE ROAD CIRCULATION CODE. FOR CHECKING AND ADJUSTING THE AIM
OF THE HEADLIGHTS, WE SUGGEST TO CONTACT A PIAGGIO DEALER OR
AUTHORISED SERVICE CENTRE.
CAUTION
13 Maintenance
BEFORE CARRYING OUT THE OPERATION FOR HEADLIGHTS AIMING, CHECK

THAT THE TYRES ARE INFLATED TO THE INDICATED PRESSURES.
104
Troubleshooting / What to do if... (13_38)
13 Maintenance
Wheel replacement
Replace the wheel as follows:
1. Stop the vehicle so that it is not a hazard for oncoming traffic and so you can replace
the wheel safely. The ground should be flat and adequately compact;
2. Pull the hand brake and engage the first gear.
3. Loosen the 5 nuts of the wheel to replace using the supplied wrench.
4. Apply the jack to the special stiffening triangles and lift the vehicle by a few centi-
metres.
5. Remove the nuts and extract the wheel.
6. Install the wheel, gradually tightening the nuts, and then lower the vehicle and
tighten them thoroughly.
105
13 Maintenance
106
Chap. 14
Spare parts and
accessories
107
Warnings
WE RECOMMEND THE USE OF "ORIGINAL PIAGGIO SPARE PARTS", THE ON-

LY ONES TO OFFER THE SAME GUARANTEE OF QUALITY AS THE ORIGINAL
PARTS INSTALLED ON THE VEHICLE. REMEMBER THAT THE USE OF NON-
ORIGINAL SPARE PARTS WILL AFFECT YOUR RIGHTS AND INVALIDATE THE
TERMS OF THE GUARANTEE
.
WARNING
PIAGGIO MARKETS ITS OWN LINE OF ACCESSORIES, WHICH ARE COVERED

BY A MANUFACTURER'S WARRANTY ON THE BASIS OF THEIR USE. IT IS
THEREFORE INDISPENSABLE TO TURN TO AN AUTHORISED PIAGGIO DEAL-
ER OR SERVICE CENTRE IN ORDER TO SELECT THEM AND HAVE THEM
CORRECTLY ASSEMBLED. USING NON-ORIGINAL SPARE PARTS CAN AF-
FECT THE VEHICLE STABILITY AND PERFORMANCE, WITH CONSEQUENT
DRIVING HAZARDS AND DRIVER SAFETY HAZARDS.
14 Spare parts and accessories
108
Chap. 15
TIPPER Version
109
System Operation (15_01)
The equipment works as follows:
1. Releasing the safety lever «B»:
Before activating the load bed tilting system, disengage the tailboard release handle
and the safety lever «B».
2. Lifting the load bed:
Pressing the «A» control pushbutton closes the electrical circuit and the battery power
activates the electrical motor and the pump. The hydraulic fluid contained in the res-
15_01 ervoir is pumped into the load bed lifting mechanism. Releasing the pushbutton stops
the load bed in any position.
3. Load bed lowering:
Pressing the «A» control pushbutton causes the hydraulic fluid to be discharged into
the by-pass distributor, which causes the load bed to lower due to its own weight.
Releasing the pushbutton stops the load bed in any position.
The tilting is controlled by the special button "A" located on the right side control panel
for the steering wheel version and above the indicator assembly for the handlebar
version.
A = Control key.
B = Safety lever.
The safety lever "B" can take two different positions:
0 = Load bed unlocked with the possibility of being tipped.
1 = Load bed locked in rest position.
15 TIPPER Version
4. Once the tilting operations have been completed move the «B» safety lever
to the 1st position.
110
15 TIPPER Version
In order to improve safety and prevent unintentional operations, the lifting control only
cabin.
• TIPPING ACTIONS OF THE PLATFORM MUST BE CARRIED OUT WHEN
THE VEHICLE IS STOPPED AND THE HANDBRAKE ENGAGED.
15_02
Safety devices
The tilting system has four components that guarantee maximum safety:
1. Safety lever «B» that locks the load bed when not engaged in tilting operations. In
fact to start any operation, the lever «B» must be moved upwards.
2. Light indicator (red coloured) positioned into the cab, which indicates the tilting of
the load bed.
3. System overpressure safety valve
4. Anti-extraction piston that allows securing the load bed in lifted and intermediate
position even while the engine is off.
Warnings for Loading and Unloading Operations (15_03, 15_04)

The operator must be in the driving position to use the equipment to be able to operate
quickly and effectively the normal and emergency controls. During the loading and
unloading operations the operator must take the following precautions.
111
• For avoiding the risk of instability during use; before carrying out loading and
unloading operations, park the vehicle on an even, horizontal surface and
check the side board and tailgate locking and blocking systems.
• Loading should be gradual and the weight of the loaded cargo must not ex-
ceed the vehicle's allowable load mass (overall and per axle). The load
should be evenly distributed on the load bed. If the load is not evenly distrib-
uted on the platform, check the following:
• abnormal stress on the mechanical parts and vehicle's instability during driv-
ing.
• abnormal stress on the equipment components and risk of vehicle overturn-
ing during the tilting operation.
• The cargo height must be proportional to the density or specific gravity of the
loaded material. The allowable load capacity is around 700 kg and propor-
tional to the cargo height.
• up to the side board rim in the case of light, loose material (grains or by-
products).
• up to the middle of the side board in the case of inert materials (sand, gravel
compost or similar materials).
• when loading blocks or objects check their position to ensure an evenly dis-
tributed load on every axle.
15 TIPPER Version
112
15 TIPPER Version
During unloading operation check:
• that the tailboard is open. Otherwise, stop the unloading operation immedi-
ately and set the load bed at rest; do not force the side boards open when
the load bed is in tilted position.
• Carry out gradual unloading until the load bed is completely empty.
• In order to avoid risks of injury to people or damage to objects due to falling
objects park the vehicle away from other people's working zone and from
objects or structures that may damage the cargo, also taking into account the
type of loaded material;
• In case of unloading the cargo inside a building, check the free ceiling height
and the distance from any other possible structural parts of the building
(pipelines, electrical conductors, etc.) in order to ensure that the load bed can
be tilted completely, also taking into account the height increase due to the
extension of the shock-absorbers In any case, do not lift the loading surface
near live electrical lines or gas pipes to avoid the risk of contact or failure to
keep a minimum safe distance.
An adequate load bed cover must be installed when transporting reduced density
loads (granular or powdered material, light material, fragments, scrap, etc.) or material
that can be lifted and blown away by the wind.
In any case, the height of the bulk material loaded must not exceed the height of the
side board.
It is strictly forbidden to stand near or underneath a lifted, loaded loading surface
without securing the safety bar and provided the vehicle is empty
It is risky to lift the load bed when the wind blows strong
15_03
113
The vehicle load must not exceed the maximum tolerances set for in the Road Reg-
ulations or the allowable tolerances specified by the manufacturer. For information on
load tolerances (overall and per axle) refer to the Technical Specifications section.
The value for the overall mass is given in the vehicle registration papers.
Remember that loading the vehicle in excess of the values given in the Traffic Regu-
lations and on the manufacturer's plate, even for short trips, runs the serious risk of
damage to the vehicle due to the excessive stress exerted on the vehicle's parts and
on the tipping components, and may also result in sanctions under Traffic Regulations
regarding overloading.
15_04
Scheduled Maintenance
CAUTION
WARNING
BEFORE CARRYING OUT ANY OPERATION WITH THE LOAD BED TILTED AND
UNLOADED, IT WILL BE NECESSARY TO FIT THE SPECIAL PROP HINGED ON-
TO THE CHASSIS AND INSERTED INTO THE ATTACHMENT UNDERNEATH THE
LOAD BED. SUCH A DEVICE MUST BE REPLACED ONLY AFTER THE OPERA-
TION HAS BEEN COMPLETED AND BEFORE THE LOAD BED IS LOWERED.
15 TIPPER Version
Counter-chassis attachments and connections to the chassis

Ensure all bolts securing the counter-chassis to the chassis are tightened and, if nec-
essary, tighten any loosen bolt.
Hinges
114
Ensure the hinges are free to move and have no excessive clearance or deformation.
15 TIPPER Version
Cylinder and jack
Check that the jack stem is properly extended and that it is free of scratches, dents or
deformations. In the event of faults, please contact the manufacturer or an authorised
workshop.
Hydraulic system piping and valves

Ensure the pipes, joints, and fittings on all components are leak free. In particular,
check the flexible pipes are not damaged. In the event of faults, please contact the
manufacturer or an authorised workshop.
Lubrication and greasing

All system moving components must be lubricated with oil or grease every 25 working
hours and again every 30 - 40 days, according to the operating environment (moist,
fine sand, dust, or polluting or corrosive substances, etc.). Lubricated pins and hinges
with suitable grease.
Hydraulic oil
Check the oil level and, if necessary, top it up. If the load bed fully tilted, take into
account the amount of oil inside the cylinder.
• Use only recommended hydraulic fluid.
• Do not mix the oil with another type.
• Replace the fluid completely every 4 years and clean the reservoir.
• Replace the oil completely every 150/200-work hours.
AGIP ARNICA 46
115
HV hydraulic oil (High viscosity index).
ISO-L-HV; DIN 51524-3 HVLP.
Pneumatic and electrical control circuits, controls and warning lights.

Check the standard operation of the controls, warning lights and relevant circuits and
pipes. In the event of faults, please contact the manufacturer or an authorised work-
shop.
Structural components
Check that all structural components are free of faults such as bending, breakage,
detached components, welding cracks etc. If any faults are noted, contact the manu-
facturer or a specialised repair centre.
Extraordinary Maintenance
Such operations consist of all interventions aimed at:
• fix leaks within the hydraulic circuit;
• checking, repairing, or replacing the hinges, pins, oil seals constituting the
tilting mechanism and lifting jack;
• checking or replacing the end-stroke device, the hydraulic control unit and
warning light;
• checking or repairing the body structure or any other component of the upper
15 TIPPER Version
structure.
The lifting system may be affected by several different causes of failure. In such cir-
cumstances, after following all instructions given within the manual, it is necessary to
carry out a troubleshooting session.
116
Trouble-Shooting
15 TIPPER Version
Body does not start lifting and control unit does not emit any noise
Possible cause:
• no supply (low battery, loose terminals).
• supply to the electrical circuit is interrupted (defective fuse, faulty switch,
loose electrical connections).
• end-stroke device jammed.
Solutions to be undertaken:
• check the battery and the supply circuits
• replace the fuse
• check the control switch
• check the end-stroke device
Body does not start lifting but there is a noise coming from the control unit
Possible cause:
• no oil in the tank
• the pipe connecting the pump to the cylinder is obstructed or leaking
• electric motor is faulty
• pump is faulty
• distributor by-pass faulty
• excessive load on body or vehicle parked on a slope
• check the oil level inside the reservoir and top-up if necessary
• check the pipes, electric motor, pump, and distributor
Body lifts only partially

Possible cause:
• early engagement of end-stroke device
• insufficient oil inside reservoir
117
• check the end-stroke device
• check the oil level
Body does not come down

Possible cause:
• control switch faulty
• clogged exhaust pipe
• by-pass defective
• check the control switch, pipes and by-pass
Body lifts without activating the controls

Possible cause:
• control switch or electric circuits defective (short-circuit)
• check the insulation of the control switch and electric circuit.
Body does not stop after releasing the pushbutton

Possible cause:
15 TIPPER Version
• distributor retaining valve defective

• check the distributor
Warning light and buzzer stay on
118
Possible cause:
15 TIPPER Version
• switch faulty
• check the switch
Warning light and buzzer not working

Possible cause:
• warning light bulb defective or buzzer faulty (if only one of the two not working)
• switch or electric circuit faulty if both not working
• check: switch, electrical circuits, warning light bulb, and buzzer
Tailgate remains shaft when body is tilted

Possible cause:
• automatic release mechanism faulty
• check possible faults or defects within the release mechanism
Tailgate remains open after body has lowered completely

Possible cause:
• automatic release mechanism faulty
• incorrect position of adjusting bolt
• check possible faults or defects within the release mechanism
• check the position of the adjusting bolt
119
Warning Plate Symbols (15_05)
All labels are fitted individually or in series in different parts of the vehicle: counter-
chassis, instrument panel, side boards, etc...
15 TIPPER Version
120
15 TIPPER Version
15_05
121
NOTE - LABELS
A READ THIS MANUAL
CAREFULLY AND FOLLOW THE
INSTRUCTIONS IT CONTAINS.
B KEEP AT A SAFE DISTANCE

FROM T HE VEHICLE
C DO NOT REST UNDER THE

LIFTED LOADING PLATFORM IF
THE SAFETY BAR HAS NOT
BEEN SECURED.
D STOP THE ENGINE AND

REMOVE THE KEY AND THE
EMERGENCY FUSE BEFORE
CARRYING OUT MAINTENANCE
OPERATIONS.
E DO NOT PARK THE VEHICLE

DOWNHILL OR ON LOOSE SOIL.
F DO NOT STAND NEAR THE

DANGER ZONE IF THE LOADING
PLATFORM IF LIFTED.
G WEAR GLOVES TO AVOID

15 TIPPER Version
CONTACT WITH HOT PARTS.
H WEAR GLOVES TO AVOID

INJURY BY HIGH-PRESSURE
FLUIDS.
122
technical sheet for EC conformity declaration
15 TIPPER Version
This manual contains information on the vehicle's tilting system.
Thorough knowledge of the manual's content is fundamental to ensure proper use and
adequate functioning of the installed equipment.
Even in the case of equipment that is easy to use, operators must be familiar with
common safety measures and must pay special attention during manoeuvring in order
to ensure proper vehicle operation at the various stages of the operating cycle. Proper
use of equipment is fundamental to avoid any possible risk and reduces the frequency
of maintenance operations, thus enhancing the durability of the vehicle's components.
The operator should carry out the various procedures very carefully to avoid injury to
himself, other people or objects. The vehicle has been designed for unloading and
transporting loose, solid material or blocks. The loading body can be tilted backwards
for cargo unloading.
The builder shall not be liable for any damage caused by failure to observe the in-
structions herein contained or caused by improper or forbidden use or damage due
to misuse, inadequate or incomplete maintenance of the equipment or the vehicle.
The builder shall not liable for any replacement, modification or tampering with vehicle
components or incorrect maintenance or repair operations carried out by unskilled
personnel using inadequate materials.
Modifying or tampering with side boards and tailgate or increasing their height with
fixed or movable parts is strictly forbidden. The builder reserves the right to authorise
any modification if it is deemed appropriate.
Preface
• Tricycle
• T1 type
• Following version: T1BR/MS - T1BR/VS
The instructions contained in this manual pertain to the tilting equipment and are aimed
at the release of the declaration of EC conformity for the vehicles built and complying
with the specifications outlined hereby. The validity of the certification is extended to
all tilting systems having the same specifications and complying to the standards set
123
forth in directive 89/392/EEC and amendments, in the 91/368/EEC, 93/44/EEC ap-
plicable standards and CUNA standards NC 173-01, 173-02, 173-03,173-04 and
173-05
.
Reference:
• drawings of the overall vehicle, the chassis, the tilting system components,
the control and safety devices.
• Illustrations of the fitted vehicle.
Equipment Layout
The tilting system consists of:
• -a base chassis (cabin with centre member);
• -a counter-chassis built with a pressed-sheet structure bolted onto the base
chassis;
• -body resting on a pressed-sheet loading platform and supported by cross-
beams and outline section bars; the front headboard and lateral boards are
fixed; the tailgate can be tilted and removed; the tailgate, which is equipped
with a mechanical closure system, can be lifted upward or downward.
The tailgate locking-release mechanism
is activated by moving a control lever.
In the body centre there are hinged bolt fittings connected to the end of the
pushing triangle (jack), fixed onto the body by means of an arc-welded press-
ed sheet structure.
• -two-position lifting jack with special fittings welded onto the base chassis
and fastened onto the abovementioned hinge with an appropriate bolt fitted
15 TIPPER Version
on the upper part

• .
124
15 TIPPER Version
1. Base chassis.
2. Lifting jack stem.
3. Safety bar.
4. Body hinges.
5. Jack upper pivot attachment
6. Body reinforcing structure.
15_06
1. Vehicle's counter-chassis
2. Safety bar support.
3. Safety bar.
4. Base chassis.
• Rear hinges fastened onto appropriate brackets, bolted onto the overhang of
rear chassis members.
15_07
1. Hydraulic fluid reservoir

2. Pump and pipe fittings connected to jack
3. Buzzer.
4. Switch for indicating lifted body and enabled vehicle start.
5. Drop valve inside the jack.
Hydraulic system consisting of:

15_08
• - hydraulic fluid reservoir,
125
• - pump driven by an electrical motor powered by the vehicle's battery, dis-
tributor fitted with a by-pass valve,
• - high-pressure pipelines connecting the pump to the jack,
• - electrical system equipped with controls and safety devices;
Safety devices consisting of:
• - switch for indicating lifted body,
• - buzzer indicating lifted body,
• - movable guard for activating the signalling switch ,
• - body release lever
• - tailgate release lever
• - drop valve mechanism of the jack, which prevents the body overtravel in
case of a hydraulic system failure,
• - manually-fitted safety bar hinged onto the body and fastened onto the coun-
ter-chassis by a retainer.
Tilting body front and locking lever.
1. Body release lever

2. Body attachment hook
3. Lever retracting spring.
4. Safety pushbutton guard.
15_09
15 TIPPER Version
126
15 TIPPER Version
Tailgate and closure mechanism
1. Tailgate
2. Locking lever hinge
3. Locking bolt for closure mechanism.
4. Locking lever
15_10
Analysis of Risks Connected with the Layout and Operation of

the Equipment
Possible risks are evaluated as per Directive no. 89/392/EEC, as modified and inte-
grated by EEC Directives 91/368, 93/44, 93/68 with regard to the layout and operation
of the equipment as applicable to the type and operational specifications of the equip-
ment itself. The operational specifications of the tilting equipment are also examined
with reference to the CUNA tables NC 173-01, NC 173-02, NC 173-03, NC 173-04,
and NC 173-05.
ESSENTIAL HEALTH AND SAFETY REQUIREMENTS.

Design and Manufacture.
The design and manufacture conform to all requirements set forth in the Directives.
They are carried out in conformity with the requirements dictated by the Italian MIN-
ISTRY OF TRANSPORT - M.C.T.C. Headquarters, and CUNA standards, where
applicable.
The main structural elements are subjected to stability calculations. The safety levels
are those imposed by the standards, imposing a safety coefficient not less than 2.5
times the yield stress of the material. The vehicle, in all its variants, has achieved the
type homologation. A declaration of conformity is released for each vehicle sold, re-
ferring to all its components according to the type ratified. The materials and compo-
nents used are those listed in the "References for Upper Structure Elements" Section.
127
The overall equipment design and manufacture, meets the requirements set forth in
section 1.1 of the Technical Appendix to the Standards, in addition to the above men-
tioned CUNA norms.
Controls and control devices.

All controls comply with the applicable Directives regarding the type and operational
specifications of the equipment and its use. Operator position: this is the vehicle driv-
er's position. Control position: on the dashboard, to the left of the driving position (for
left-hand drive vehicles) or in the opposite position for right-hand drive vehicles.
Controls to be used by operator:
• there is a single control for lifting or lowering the load bed.
• a device fitted with an emergency system. This control is a pushbutton loca-
ted in the electrical circuit that connects the battery to the hydraulic control
unit. This protected circuit is derived from the vehicle's circuit and has two
sections:
• one section supplies the electrical motor connected to the pump.
• the other one activates the control distributor by-pass.
The control has two properly labelled positions:
• upward arrow indicating lifting.
• downward arrow indicating lowering.
In the resting position the electrical circuits of both sections remain open: the engine
is not powered and the by-pass remains closed.
Pushing the switch upwards (as shown by the arrow) closes the load bed supply sys-
15 TIPPER Version
tem. The switch has a latching function. Releasing the switch stops the load bed.
Moving the switch downwards (as shown by the arrow) opens the load bed distribution
by-pass and starts (or continues) the load bed lowering operation.
The switch has a latching function. Releasing the switch stops the load bed. There
are red-light indicators (located on control pushbutton and marked with a symbol in-
dicating lifted load bed) and buzzers that can be heard even from inside the cabin.
128
The warning indicators are turned on by pressing a pushbutton when disengaging the
15 TIPPER Version
load bed release lever at the beginning of the lifting operation, and they remain illu-
minated until the release lever is re-engaged.
The warning lights and buzzers are activated as soon as the load bed lifting operation
starts and are deactivated when the load bed reaches its home position.
The hydraulic system efflux lights have been properly adjusted according to the load
bed lifting and lowering speed in order to avoid causing undesired stress and hazards,
even in case of lifting system failure. The load bed lifting or lowering movements are
slow enough to allow the operator to take prompt action in case of incorrect vehicle
handling or any other failure.
The emergency control has a removable valve located in the electrical supply circuit,
which cuts out power supply, if required. The device can be easily reached and is easy
to remove and remount.
All controls and hydraulic equipment comply with the above mentioned CUNA stand-
ards.
PROTECTION MEASURES AGAINST MECHANICAL RISKS

Vehicle's stability
Because of its capability of transporting and unloading cargo through load bed tilting,
this vehicle presents risks of instability, which may be avoid only through careful op-
eration of the equipment when loading and unloading. Conditions of instability may
arise as a result of the irregularity, non-planarity, or poor consistency (collapse) of the
ground underneath the vehicle, in addition to the failure of the tailgate release and
locking system. As a result of the lightweight load bed construction, instabilities may
arise in windy conditions or in the event that the load is not evenly distributed.
The tailgate lock system is designed so that:
• The tailgate remains shut when the load bed is at rest;
• And it opens automatically, through the automatic release mechanism, as
soon as the load bed starts lifting.
129
Precautions for avoiding the risk of instability during use
The precautions to be adopted are given in the instructions and concern the following:
• Position of the vehicle during the loading and unloading operations, in par-
ticular, the nature of the wheels' resting surface (non-planarity, irregularity,
and poor consistency).
• Loading method with particular reference to the entity, gradualness, and dis-
tribution of the cargo.
• Unloading warnings and operations, with particular reference to the auto-
matic release of the tailgate and the intervention of the end-stroke device.
There are warning plates with writings or symbols referring to the above
mentioned requirements.
Risk of system breakdown during operation

The system is designed and manufactured to withstand the loads experienced during
the circulation and the loading and unloading operation, as set forth in the standards.
However, it is possible that, following the collapse of a structural element, as a result
of overloading or uneven load distribution, or other external causes, the load bed flips
backwards or sideways.
Precautions for avoiding the risk of failure during use

• Knowledge of the maxim allowed loads for the vehicle (overall and per axle):
registration papers, and plate in accordance with EEC Directives 76/114 and
15 TIPPER Version
78/507.
• Compliance with the maximum load restrictions, particularly the load bed ca-
pacity and load bed height as a function of the density of the material.
• Compliance with the requirements concerning the distribution of the load over
the load bed.
• Regular operational inspections of the end-stroke and tailgate automatic re-
lease devices.
130
There are warning plates with writings or symbols referring to the above mentioned
15 TIPPER Version
requirements.
Risks associated to falling or flying objects

During loading, unloading, or transport, there is a risk of objects falling off the load
bed. Such risk may be avoided solely by taking adequate precautions against such
contingencies.
Risks associated to falling or flying objects.

• Park the vehicle sufficiently far from any workplace or damaging objects.
• Forbidding anyone from approaching the vehicle during unloading.
• Forbidding anyone from approaching the open tailgate during unloading and
taking any action to facilitate the fall of the material.
• Forbidding loading the vehicle above the gates' height.
• Special requirements apply to the transport of lightweight materials. There
are warning plates with writings or symbols referring to the above mentioned
requirements.
Risks due to sharp edged surfaces and angles.

Some components and accessories may pose the risk of injury by accidental collision.
Violent collision with metal vehicle parts or accessories, even if these do not have
sharp-edged angles or cutting sections, may cause bruises or injuries.
Precautions for avoiding the risks of injury by sharp-edged surfaces or angles.
Safety measures to take into account when operating near exposed vehicle parts or
equipment components.
• wear personal protection equipment, particularly during side board removal
or when carrying out maintenance operations.
131
Protection measures against mechanical hazards comply with the requirements set
forth in the Directive's technical appendix on "safety measures to avoid mechanical
risks" and the above mentioned CUNA standards.
Protective Measures Against Other Hazards

The equipment is driven by hydraulic fluid, which may reach high temperatures during
operation, resulting in the danger of burns in the event of leaks from pipes, valves, or
fittings. Risk of fire may also result from the fluid coming into contact with high tem-
perature components (e.g. exhaust pipe). Shields of isolating material are located near
hot engine parts or exhaust pipe. When unloading indoors the lifted load bed may hit
the ceiling or other obstacles.
Precautions for avoiding other hazards

• Checking the free ceiling height and the distance from any other possible
structural parts of the building in order to ensure that the load bed can be
tilted completely, also taking into account the height increase due to the ex-
tension of the shock-absorber.
• Forbidding anyone from approaching pressurised hydraulic circuits.
• Forbidding load bed lifting near live electrical lines or gas pipes, to avoid the
risk of contact or the observance of the safety distance.
• Forbidding the operation in areas with insufficient lighting.
Protection measures against other hazards comply with the requirements set forth in
the Directive's technical appendix and the above mentioned CUNA norms.
15 TIPPER Version
Maintenance
Operational maintenance does not involve any risk as it only consists of visual checks
and the greasing of parts subjected to wear (e.g. tipping hinges, side and tailgate
hinges, hooks and locks), if necessary. Inspecting the counter-chassis attachments
does not involve any risk for as long as the load bed is at rest.
132
All operations requiring the load bed to be lifted, for whatever reason, must only be
15 TIPPER Version
carried out after the safety prop has been carefully positioned underneath the load
bed. The safety prop prevents the load bed from dropping. It does not offer the same
safety guarantee when the load bed is loaded. For other maintenance operations or
repairs, which require intervention on elements of the upper structure when the load
bed is lifted (e.g. fixing of lifting jack and accessory components, pins and hinges
replacement), it is mandatory to refer to an authorised workshop equipped with all
necessary tools and safety equipment.
Information regarding maintenance is given in the instructions.
Marks and signals

The following instructions contain information regarding equipment operation. The
following specifications are indicated on the plate:
• manufacturer's name and address
• CE marking and year of manufacture
• vehicle type and chassis identification number
• device serial number
Conclusions
The overall equipment and all its components comply with the specifications and
standards set forth in Directive 89/392/EEC and amendments and 91/368/EEC, 93/44/
EEC, 93/68/EEC, in addition to CUNA standards NC 173-01, 173-02, 173-03,173-04
and 173-05.
N.B.
FOR INFORMATION ON LOAD TOLERANCES (OVERALL AND PER AXLE) RE-
FER TO THE REGISTRATION PAPERS OR THE TECHNICAL SPECIFICATIONS
SECTION.
PLATES CONTAINING COMMONLY USED WARNING MESSAGES AND SIGNS
ARE LOCATED NEAR VARIOUS EQUIPMENT PARTS
.
133
NOTE: For the total mass and the mass on the relative axes, reference should be
made to what indicated on the label installed on board the vehicle. In addition, at
several points of the device, there are adhesive warning labels with symbols of com-
mon use.
15 TIPPER Version
134
Chap. 16
Technical data
135
VEHICLE LENGTH A
NORMAL BODY 3175 mm
LONG BODY 3390 mm
TILTING BODY 3225/3335 mm(*)
VAN 3210 mm
MOTOR CHASSIS 3150/3210 mm
VEHICLE WIDTH B
NORMAL BODY 1480 mm
LONG BODY 1500 mm
TILTING BODY 1500 mm
VAN 1480 mm
MOTOR CHASSIS 1455 mm

16 Technical data
VEHICLE HEIGHT C
NORMAL BODY 1630 mm
LONG BODY 1630 mm
TILTING BODY 1630 mm
136
VAN 1780 mm
16 Technical data
MOTOR CHASSIS 1630 mm
VEHICLE WHEELBASE D
NORMAL BODY 2170 mm(Ο) - 2130 mm(∆)
LONG BODY 2170 mm(Ο) - 2130 mm(∆)
TILTING BODY 2170 mm(Ο) - 2130 mm(∆)
VAN 2130 mm (Ο)
MOTOR CHASSIS 2170 mm(Ο) - 2130 mm(∆)
LOAD COMPARTMENT LENGTH E

NORMAL BODY 1770 mm
LONG BODY 1970 mm
TILTING BODY 1810/1920 (*) mm
VAN 1770 mm
LOAD COMPARTMENT LENGTH F

NORMAL BODY 1420 mm
LONG BODY 1970 mm
137
TILTING BODY 1810/1920 (*) mm
VAN 1770 mm
Vehicle (16_01)
(*) For Diesel versions only.
(O) Handlebar.
(∆) Steering wheel.
16 Technical data
138
16 Technical data
16_01
139
TECHNICAL SPECIFICATIONS - PERFORMANCE
Engine Single cylinder, two strokes, with
revolving timing system with three
transfer ducts.
Bore 68 mm
Stroke 60 mm
Displacement 217.9 cm3
Compression ratio 8.6 : 1
Ignition advance (before TDC) 14°±1°30"
Carburettor Dellorto SHBC 22/22
Spark plug BOSCH W3AC - CHAMPION

RL78C - NGK BR8HS
Engine-wheel transmission ratio - 1st speed = 1/48.47

- 2nd speed = 1/26.54
- 3rd speed = 1/15.57
- 4th speed = 1/9.16
- RM = 1/80.78
Max. speed 60 - 65 km/h

16 Technical data
REFUELLING
Gasoline RESERVE: 3.5 litres
140
CAPACITY (including reserve):
16 Technical data
15 litres
Mixer oil RESERVE: 0.75 litres

CAPACITY (including reserve): 3
litres
Gearbox oil CAPACITY (including reserve):

1000 cc
VERSION
Normal body LOADLESS WEIGHT(with
driver): 465 kg
CAPACITY (excluding driver):
805 kg
MAX WEIGHT: 1270 kg
Long body LOADLESS WEIGHT (with

driver): 465 kg
805 kg
MAX WEIGHT: 1270 kg
Tilting body LOADLESS WEIGHT (with

driver): 505 kg
765 kg
MAX WEIGHT: 1270 kg
141
Van LOADLESS WEIGHT (with
driver): 505 kg
765 kg
MAX WEIGHT: 1270 kg
Fixed motor chassis MAX WEIGHT: 1270 kg
Tilting motor chassis MAX WEIGHT: 1270 kg
TECHNICAL SPECIFICATIONS - PERFORMANCE

Engine Diesel cycle, 4 strokes, indirect
injection, single cylinder
Bore 83 mm
Stroke 78 mm
Engine capacity 422 cm3
Compression ratio 23 : 1
Static start advance 11° - 24° before TDC
Dynamic advance 13° - 25° ±1 before TDC

16 Technical data
Engine-wheel transmission ratio - - 1st speed = 1/39.8

5 gear version (Steering wheel) - 2nd speed = 1/24.7
- 3rd speed = 1/15.8
- 4th speed = 1/10.4
- 5th speed = 1/6.8
142
- RM = 1/39.8
16 Technical data
Engine-wheel transmission ratio - - 1st speed = 1/35.4
4 gear version (handlebar) - 2nd speed = 1/19
- 3rd speed = 1/10.9
- 4th speed = 1/7.1
- R.M. = 1/35.4
Maximum speed ~ 65 km/h
REFUELLING
Diesel CAPACITY 15 litres (reserve: 3.5
litres)
Engine oil CAPACITY: 2.8 lt. (3.5 tot. system)
VERSION
Long body LOADLESS WEIGHT (with
driver): 515 kg
755 kg
MAX WEIGHT: 1270 kg
Tilting body LOADLESS WEIGHT (with

driver): 555 kg
143
715 kg
MAX WEIGHT: 1270 kg
Motor chassis MAX WEIGHT: 1270 kg
TECHNICAL SPECIFICATIONS
Fuel supply By an injection pump, fed by a
membrane pump.
Fuel Automotive diesel
Lubrication Pressure by lobe pump.
Oil filter With cartridge and total capacity.
Timing system Camshaft on the cylinder head,

controlled by a toothed belt.
Water cooling, Permanent forced coolant

circulation system.
Air filter With dry filtering cartridge.
Transmission From crankshaft to the rear wheels

via clutch, assembly of gearbox -
differential - axle shafts and flexible
couplings.
16 Technical data
Clutch Single disc with lever control (left

side of the handlebar) or by pedal
for the steering wheel version;
adjustable flexible transmission.
Gearbox With four gears on the handlebar

version with always driven gears.
144
With 5 gears on the steering wheel
16 Technical data
version.
Differential Connected to the gearbox shaft by

cylindrical gears. The planetary
and satellite gears are bevel.
The differential box is connected to
the two axle shafts that transmit the
motion to the wheels by flexible
couplings. The differential is
equipped with a gear reversing
device.
Start up With electric motor and key control.
Exhaust silencer Expansion and absorption-type

exhaust silencer.
Steering and suspensions Steering wheel tube pivoted on the

arm with front wheel-holder
oscillating hub. Front suspension
with helical spring and hydraulic
coaxial shock absorber. To
compensate the suspension load,
the front wheel is tilted by approx.
1.5° relative to the vertical axle.
Independent rear suspensions
with oscillating triangular arms with
rubber pad and variable flexibility
at each wheel; the hydraulic shock
absorbers are coaxial to the spring
members.
The rear suspensions are
manufactured so as to have a
longer stroke than the former
models, to improve driving comfort.
With stationary and loadless
vehicle, the wheel setup is inclined
by about 6.5º in relation to said
145
stroke; in full load condition, the
wheels have a vertical setup.
Brakes With expansion on the three

wheels:
Front and rear with hydraulic
control by pedal and direct
controlled brake pump.
- Safety or parking with mechanical
control on the rear wheels. The
control lever is located on the
central instrument panel column in
the driving cabin. The brakes are
provided with a shoe self-
adjustment device that
automatically and continuously
restores the proper clearance
between blocks and drums,
regardless of the friction material
wear.
Wheels Pressed sheet metal rim 3.50-12
Front tyre - Handlebar 4.00-12CN TL
Rear tyre - Handlebar 125R12C XZX TL
Front tyre- Steering wheel 125R12C XZX TL
Rear tyre - Steering wheel 125R12C XZX TL

16 Technical data
Injection system In the diesel engine, the fuel is

injected at the end of the
compression stroke in the pre-
chamber through the injection
pump.
146
The amount injected for each cycle
16 Technical data
is adjusted, depending on the
power required, through the
rotation of the pumping element of
the injection pump by the
adjustment bar.
Fuel supply control The adjustment bar is actuated by

the regulator. It is flanged on the
side of the engine head and is
pulled by a shaft actuated by the
camshaft.
The main functions of the regulator
are:
• Adjusting the engine idle
speed;
• Maximum engine speed
limitation;
• Increase of the capacity
during start up
.
Toolkit A lifting jack.

A pipe wrench with 17-21 mm
apertures.
A dual screwdriver (for cross
slotted and straight screws).
A 12 mm wrench for preheat glow
plug removal.
147
16 Technical data
148
Chap. 17
Scheduled
maintenance -
Checks
149
Scheduled maintenance service
SERVICE SCHEDULE
Adequate maintenance is fundamental to ensure long-lasting, optimal operation con-
ditions and performance.
For this purpose, PIAGGIO offers a series of checks and maintenance operations to
be performed at the owner's expense, which are summarised in the table on the next
pages.
Any minor faults should be reported without delay to an Authorised Piaggio Dealer
or Service Centre without waiting until the next scheduled service to solve it.
Service the vehicle at the prescribed mileage.
The warranty will not apply unless the Scheduled Services, specified for the guarantee
period you choose, are carried out.
Failure to carry out the scheduled services will automatically invalidate the warranty.
For further information regarding Warranty procedures and «Scheduled Mainte-
nance», please refer to the «Warranty Booklet».
17 Scheduled maintenance - Checks
MAINTENANCE OPERATIONS (gasoline version)
AT 1,000 KM
Braking system - vehicle test/check
Locking external nuts and bolts - check
Parking brake - check/adjust
Brake pump tank oil level - check
150
Gearbox, gas and clutch control - check/adjust

Belt tension - tension check/adjust
Electric system and batteries - efficiency check
Gearbox oil - replacement
Headlights - check/adjust
Idle carburation - check/adjust
Tyre pressure - check
AT 4,000 KM AT 20,000 KM AT 28,000 KM AND AT

44,000 KM
Spark plug - check/clean/electrodes adjustment
Battery - check/top up
Levers and engine side controls - lubricate
Differential gearbox unit oil level - check
Carburation - check
Carburettor - Cleaning
Hinges and door closures - lubricate
151
Air filter and SAS box (sponge) - clean
SAS reed support - check
AT 8,000 KM AT 16,000 KM AT 32,000 KM AND AT

40,000 KM

Cylinder head, piston head, discharge lights, exhaust pipe - clean
Carburation - check
152

AT 12,000 KM AND AT 36,000 KM

Carburation - check
SAS reed support - replacement
153
AT 24,000 KM AND AT 48,000 KM

Cylinder head, piston head, discharge lights, exhaust pipe - clean
Carburation - check
154
SAS reed support - replacement

Scheduled maintenance service
DIESEL VERSION
AFTER 1,000 KM
Braking system - Test drive - Inspection
Brake fluid level - Check
External nuts and bolts lock - Inspection
Tappets - Inspection/Adjustment
Gearbox, gas and clutch control - Inspection/Adjustment
Electric system and batteries - Efficiency check
Injection dynamic advance and timing belt tension - Inspection
Tyre pressure - Inspection
Engine oil - Replacement
Oil filter - Replacement
AT 5,000 KM; AT 15,000 KM; AT 25,000 KM; AT 35,000 KM; AT

45,000 KM AND AT 60,000 KM
155
Preheat glow plug - Inspection
Cylinder head, piston head, exhaust pipe, water radiator - Cleaning
Levers and controls engine side - Greasing
AT 10,000 KM; AT 30,000 KM AND AT 50,000 KM

156

Engine oil level - Inspection
Hinges, door closures and flexible transmissions - Greasing
Fuel filter - Replacement
Air filter - Replacement
Cooling circuit pipes - Inspection
AT 20,000 KM; AT 40,000 KM AND AT 70,000 KM

Hinges, door closures and flexible transmissions - Greasing
Cooling circuit pipes - Inspection
157
Fuel filter - Replacement
Air filter - Replacement
Coolant - Replacement
RECOMMENDED PRODUCTS
Product Description Specifications
AGIP CITY TEC 2T Oil for 2-stroke petrol engines JASO FC, ISO-L-EGD Specifications
AGIP ROTRA MP 80W-90 Oil with specifications SAE 80W-90, API GL-5 Gearbox oil
AGIP BRAKE 4 Brake fluid Specifications - FMVSS DOT 4

AGIP GREASE PV 2 Multipurpose grease NLGI 2 specifications; ISO-LXBIB2
AGIP ARNICA 46 Oil for hydraulic tilting system pump Oil for hydraulic circuits corresponding to
specific ISO VG 46, DIN 51524 HVLP
AGIP SUPERDIESEL MULTIGRADE 15W-40 Engine oil (recommended for warm climates) SAE 15W-40, API CF-4/SG
158
TABLE OF CONTENTS
B I P Wheel: 39, 41, 72

Belt: 33, 34 Identification: 7, 8 Pressure: 92 Windows: 29
Instrument panel: 35
C S
Checks: 14, 149 K Safe riding: 11
Control: 57 Keys: 28 Safety: 31–34
Safety belts: 31, 32
Seats: 31
D L Switch: 53
Doors: 27 Level: 76, 79–81, 83 System: 57, 67, 91, 110
Lights: 55
Locks: 27
E T
Engine: 18–21, 30, 76, 84 Tyres: 91
M
Maintenance: 72, 75, 114,
F 116, 149, 150, 155 V
Filter: 76, 78, 85 Mirrors: 61 Vehicle: 8, 13, 138
Fluid: 79, 80, 83, 84
Fuel: 68, 85, 86
Fuses: 88 O W
Oil: 76, 78, 81 Warning: 55, 120
159
© Copyright 2012 - PIAGGIO & C. S.p.A. Pontedera.
All rights reserved. No part of this publication may be reproduced.
This publication has been edited by:
After sales - PIAGGIO & C. S.p.A.
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
ITALY
www.piaggio.com

APE TM, TM Diesel Owners Manual PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

APE TM, TM Diesel Owners Manual PDF

Uploaded by

Copyright:

Available Formats

Piaggio would like to thank you

Ape TM - Ape TM Diesel

Safeguarding the environment

The incomplete or non-observance of these regulations leads to the risk of serious

The gasoline version engine identification initials are:

TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD.

Rear tyre pressure 4.5 atm

BEFORE REFUELLING, STOP THE ENGINE. PETROL IS HIGHLY INFLAMMA-

Fuel (Unleaded petrol)

Oil tank (for petrol versions)

USING OTHER TYPES OF OIL CAN COMPROMISE ENGINE DURABILITY.

AGIP CITY TEC 2T

Removing the battery

NEVER DISCONNECT THE BATTERY WHEN THE ENGINE IS RUNNING TO

BATTERY ELECTROLYTE CONTAINS SULPHURIC ACID: AVOID CONTACT

USED BATTERIES ARE HARMFUL FOR THE ENVIRONMENT AND MUST BE

DO NOT INVERT THE POLARITIES: DANGER OF SHORT-CIRCUIT AND FAULTS

Checking electrolyte level

Before starting the engine

THIS PRELIMINARY OPERATION IS NOT REQUIRED IN THE STEERING WHEEL

EXHAUST GASES ARE TOXIC. DO NOT START THE ENGINE IN A CLOSED

WHEN THE ENGINE IS ON, DO NOT HANDLE PARTS AND CONNECTIONS OF

Engine start up (03_06, 03_07)

EXHAUST GASES ARE TOXIC. DO NOT START THE ENGINE IN A CLOSED

Engine start up (03_07, 03_08)

Engine start up (03_08, 03_09)

Stopping the engine (steering wheel)

NEVER STRESS THE ENGINE AT LOW TEMPERATURES IN ORDER TO AVOID

• AFTER A LONG JOURNEY ALLOW THE ENGINE TO RUN AT IDLE

Gear position (03_10, 03_11, 03_12)

Door locking/unlocking by key (04_02, 04_03)

Front door windows (04_04)

5 Seats and safety belts

Fasting the safety belt (05_01)

TO GUARANTEE THE OPTIMAL PERFORMANCE OF THE SEAT BELT, AFTER

To release the safety belt (05_03)

13. Brake pedal

Handlebars (06_01, 06_02)

Steering wheel (06_03)

Steering wheel (06_03, 06_04)

Controls (06_05, 06_06, 06_07, 06_08, 06_09)

Light selector «A»

Emergency light switch «B»

Rear fog light switch «A»

STEERING WHEEL VERSION - GASOLINE

Flashing light switch lever «C»

External light control switch «A»

Windscreen wiper control switch «B»

Rear fog light switch «C»

6 Instrument panel and controls

Controls (06_09, 06_10, 06_11, 06_12, 06_13, 06_14)

Light selector «A»

Rear fog light switch «A»

Heater fan switch «B»

Emergency light switch «A»

STEERING WHEEL VERSION - DIESEL

3 = High beams on.

Flashing light switch lever «C»

6 Instrument panel and controls

Windscreen wiper control switch «B»

Rear fog light switch «C»

Heater fan switch «D»

Emergency light switch «F»